WCM - Foundry Engineer

Weatherly Casting & Machine Co Careers•Weatherly, PA

About The Position

The Foundry Engineer is responsible to provide service in support of quality and engineering initiatives by focusing on foundry process, controls and procedures. The ultimate goal is to achieve customer satisfaction through supporting a robust quality management system An employee assigned to this title shall perform a majority, but may not perform all, of the duties listed in this job description. Conversely, minor level duties performed on the job may not be listed. · Work in a safe manner with a goal of zero harm. · Create safety awareness by actively observing, auditing, and coaching safe work behaviors and conditions. · Ensure compliance with safety and environmental rules and regulations. · Develop gating and riser systems that produces high quality castings using 3D modelling in simulation software. · Develop and design tooling (patterns and coreboxes) of 3D sand printed cores and molds in accordance with developed gating and riser plans. · Create process control sheets for molding, core making and 3D sand printing. · Participate in the evaluation and implementation of emerging technologies such as 3D scanning, 7-axis mold milling, 3D sand printing, automatic grinding systems, etc… · Inspect and test various products and materials using metrology equipment, magnetic particle, dye penetrant, hardness testing, and mechanical testing. · Test and report material conformance to customer requirements. · Create quality documentation and development of SOPs, mainly but not limited to foundry processes · Contribute to team effort by accomplishing related results as needed. · Be an active member of internal ISO team. · Analyze data and provide focus area for process improvements. · Perform internal and external audits. · Prepare reports by collecting, analyzing, and summarizing data; make recommendations · Maintain professional and technical knowledge by attending educational workshops, reviewing professional publications, establishing personal networks, benchmarking state-of-the-art practices, and participating in professional societies · Coordinate with department heads and supervisors in resolving production planning and control issues, as needed. · Communicate process improvements to supervisors and department heads on a regular basis. · Participate in developing and maintaining procedures, practices, and controls. · Communicate project status and progress on a timely basis. · Evaluate and assist in implementing cost cutting, productivity, and efficiency methods. · Prioritize projects and coordinate activities with other departments and organizations within and outside the organization. · Ensure proper execution of policies and procedures within areas of responsibility. · Must have good attendance and be reliable. · All other duties as assigned.

Requirements

ASNT Level II nondestructive testing certification for MPT and DPT.
Knowledge of metal casting processes and other manufacturing processes.
Knowledge of Odyssey ERP system.
Knowledge of ISO manufacturing methods and procedures.
Knowledge of ISO Quality System Requirements.
Knowledge of raw materials, production processes, quality control, costs, and other techniques for maximizing the effective manufacture and distribution of goods.
Knowledge of the chemical composition, structure, and properties of substances and of the chemical processes and transformations they undergo. This includes use of chemicals and their interactions, danger signs, production techniques, and disposal methods.
Knowledge of business and management principles involved in resource allocation, leadership, production methods, and coordination of people and resources.
Quality Control Analysis – Conduct tests and inspections of products or processes to evaluate quality or performance.
Complex Problem Solving – Identifying complex problems and reviewing related information to develop and evaluate options and implement solutions.
Critical Thinking – Using logic and reasoning to identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems.
Ability to analyze information and report test results.
Ability to promote process improvement, develop standards, and manage processes.
Ability to support innovation in the work environment.
Ability to use inductive reasoning to combine pieces of information to find a relationship among seemingly unrelated events.
Ability to develop and prepare process documentation, technical reports, and presentations.
Ability to communicate information and ideas in speaking so others will understand.
Ability to establish and maintain effective working relationships with supervisors and senior managers, as well as employees.
Ability to operate a personal computer and secure information from established data processing, spreadsheet, word processing, statistical software, database and graphics programs.
Ability to express ideas and communicate orally and in writing.
Ability to read, write, speak, understand, or communicate in English sufficiently to perform the duties of this position. American Sign Language or Braille may also be considered as acceptable forms of communication.
Understanding of plant equipment and production process.
Bachelor’s Degree in a discipline of engineering
ASNT Level II non-destructive testing certification for MPT and DPT
ISO certification experience

Nice To Haves

Experience with Odyssey ERP preferred
Three (3) to five (5) years of relevant foundry or manufacturing experience preferred
Equivalent combination of education and experience

Responsibilities

Work in a safe manner with a goal of zero harm.
Create safety awareness by actively observing, auditing, and coaching safe work behaviors and conditions.
Ensure compliance with safety and environmental rules and regulations.
Develop gating and riser systems that produces high quality castings using 3D modelling in simulation software.
Develop and design tooling (patterns and coreboxes) of 3D sand printed cores and molds in accordance with developed gating and riser plans.
Create process control sheets for molding, core making and 3D sand printing.
Participate in the evaluation and implementation of emerging technologies such as 3D scanning, 7-axis mold milling, 3D sand printing, automatic grinding systems, etc…
Inspect and test various products and materials using metrology equipment, magnetic particle, dye penetrant, hardness testing, and mechanical testing.
Test and report material conformance to customer requirements.
Create quality documentation and development of SOPs, mainly but not limited to foundry processes
Contribute to team effort by accomplishing related results as needed.
Be an active member of internal ISO team.
Analyze data and provide focus area for process improvements.
Perform internal and external audits.
Prepare reports by collecting, analyzing, and summarizing data; make recommendations
Maintain professional and technical knowledge by attending educational workshops, reviewing professional publications, establishing personal networks, benchmarking state-of-the-art practices, and participating in professional societies
Coordinate with department heads and supervisors in resolving production planning and control issues, as needed.
Communicate process improvements to supervisors and department heads on a regular basis.
Participate in developing and maintaining procedures, practices, and controls.
Communicate project status and progress on a timely basis.
Evaluate and assist in implementing cost cutting, productivity, and efficiency methods.
Prioritize projects and coordinate activities with other departments and organizations within and outside the organization.
Ensure proper execution of policies and procedures within areas of responsibility.
Must have good attendance and be reliable.
All other duties as assigned.