Senior Process Development Engineer Jobs in Madison, WI

Description

Baker Manufacturing Company

Job Description

Job Title: Senior Metallurgical Engineer
Department: Operations - Foundry
Reports To: VP of Operations
FLSA Status: Exempt

Position Summary

Baker Manufacturing is seeking an experienced Senior Metallurgical Engineer to provide technical leadership for our gray and ductile iron green sand foundry. This position combines metallurgical expertise with significant manufacturing process engineering responsibilities to improve foundry performance, optimize manufacturing processes, enhance product quality, and support continuous improvement initiatives.

Working closely with Operations, Engineering, Quality, Maintenance, and Production teams, this individual will lead efforts to improve manufacturing processes, reduce variation, optimize casting performance, solve complex technical challenges, and drive operational excellence throughout the foundry.

We recognize that many exceptional foundry professionals have developed their expertise through years of hands-on experience. A bachelor's degree in Metallurgy, Materials Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field is preferred; however, equivalent foundry experience and demonstrated metallurgical expertise may be considered in place of a formal engineering degree.

Qualifications

Qualified candidates will possess:

Bachelor's degree in Metallurgy, Materials Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field, or equivalent foundry experience.

Minimum of three (3) years of experience in a gray and/or ductile iron green sand foundry.

Strong knowledge of metallurgy, melt practices, iron chemistry, foundry operations, and manufacturing process improvement.

Experience with green sand testing, process control, and metallurgical analysis.

Knowledge of laboratory testing including spectrometer analysis, microstructure evaluation, hardness testing, and mechanical testing.

Experience analyzing casting defects and implementing root cause analysis and corrective actions.

Experience supporting manufacturing quality systems and continuous improvement initiatives.

Strong analytical, troubleshooting, and data analysis skills.

Excellent verbal and written communication skills.

Ability to lead, coach, and develop technical personnel.

Working knowledge of ISO 9001 quality systems is preferred.

Essential Responsibilities

Provide technical leadership for gray and ductile iron melt chemistry, metallurgical properties, and manufacturing processes throughout the foundry.

Lead manufacturing process improvement initiatives to optimize casting quality, improve productivity, reduce scrap, minimize manufacturing variation, and improve operational efficiency.

Monitor and improve green sand systems and overall foundry process performance.

Analyze casting defects, determine root causes, and implement sustainable corrective actions.

Identify, lead, and implement continuous improvement projects focused on quality, productivity, cost reduction, efficiency, and process optimization.

Monitor production data, manufacturing trends, and quality metrics to identify opportunities for improvement.

Maintain chemical and mechanical certification programs.

Support pattern layouts, tooling improvements, and process development for new and existing products.

Update manufacturing routings, bills of material, and process documentation to reflect process improvements.

Develop, maintain, and improve standard operating procedures and work instructions.

Evaluate and implement new technologies related to foundry process control, metallurgy, and manufacturing improvements.

Partner closely with Operations, Engineering, Maintenance, Production, and Quality teams to resolve technical manufacturing issues and improve plant performance.

Supervise, coach, train, and develop Foundry Laboratory Technicians, including scheduling, performance management, and daily technical support.

Provide metallurgical and technical training for supervisors, technicians, and production personnel.

Support customer quality investigations and corrective action activities.

Drive initiatives to improve Cost of Quality, reduce PPM, and increase customer satisfaction.

Ensure compliance with ISO 9001 quality standards and internal quality management systems.

Promote a safe working environment while supporting Baker Manufacturing's culture of teamwork, accountability, and continuous improvement.

Perform other duties and special projects as assigned.

Benefits

Baker Manufacturing offers a competitive compensation and comprehensive benefits package, including:

Competitive salary

Medical, Dental, and Vision Insurance

Health Savings Account (HSA) with Company Contribution

Flexible Spending Accounts (FSA)

Company-Paid Life Insurance

Company-Paid Short-Term Disability

Long-Term Disability Insurance

401(k) with Company Match

Paid Vacation

Paid Holidays

Employee Assistance Program (EAP)

Career Development and Training Opportunities

Stable, family-owned manufacturing company with over 145 years of manufacturing excellence

Physical Requirements & Work Environment

This position requires work in both office and manufacturing environments. The employee must be able to regularly stand, walk, sit, bend, climb stairs, and occasionally lift up to 50 pounds. The role requires working safely around moving mechanical equipment, molten metal operations, airborne particles, elevated noise levels, and varying temperatures while following all safety procedures and required personal protective equipment (PPE) guidelines.

Reasonable accommodations may be made to enable qualified individuals with disabilities to perform the essential functions of the position.

Baker Manufacturing is an Equal Opportunity Employer. We celebrate diversity and are committed to creating an inclusive workplace where all employees can contribute and succeed.