Foundry Engineer II

SUMMARY

The Foundry Engineer II is responsible for foundry process design and development, installation of equipment, coordination of equipment and process start-up for the Dickeyville Foundry.

ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.

Process Design and Development:

- Assist the Dickeyville team with completion of process designs

- Provide direction for outside designers for foundry processes

- Coordinate with the Dubuque foundry to achieve the best process design

Installation of equipment:

- Coordinate equipment installation with outside contractors

- Assist skilled trades with final connections to the equipment

Equipment and Process Start-up:

- Coordinate equipment start-up activities with outside contractors

- Document equipment operator responsibilities

- Document process settings and desired performance

Transition into Process Ownership

- Owner of one or more processes

- - Sand and molding, core making, melting and pouring, and post cast processing.

- Process FMEAs (Failure Mode and Affects Analysis).

- Process Control plan and control charts in conjunction with Quality.

- Lead and manage process improvement.

- - Sand stability and improvement.

- Core making, molding, pouring, and melt practices.

- Post cast improvements in safety, quality, productivity and cost reductions.

- Lead safety, cost saving and process improvement projects.

- - Automation projects.

- PQPC projects.

- Work with Engineering on design for manufacturability, automation, and improved processes.

Scrap and Re-work Reduction:

- Lead and manage the systematic reduction of scrap and re-work.

- Coordinate and analyze Designed Experiments (DOE) for improved quality and productivity.

- Work with Quality on flow and solidification simulation and analysis.

Automation and Continuous improvement:

- Find, lead, and manage continuous improvement and automation projects.

o Manage the project from concept and design to implementation phases.

o Project management and implementation.

- Continuously improve PQPC (People, Quality, Productivity and Cost).

Use PQPC, data and statistics to make decisions, lean manufacturing, DOE, and teamwork.

An understanding of A.Y. McDonald product, manufacturing processes used to produce them, and the methods used to install them.

Ability to balance and complete multiple projects ensuring the priority of PQPC.

Utilize existing company resources to create variations of existing processes in an efficient and timely manner.

Assist in training and mentoring A.Y. McDonald personnel including Foundry technicians, Co-Ops, and Interns.

Listen to, evaluate, and react to the needs of the Customer, Engineering, Quality, Manufacturing, Purchasing, Finance and Production.

Understanding and execution of Confidentiality boundaries of A.Y. McDonald information.

QUALIFICATIONS

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

EDUCATION and/or EXPERIENCE

Requires a B.S. in Engineering from a four year College or university. Minimum of 3 years of Foundry/Process Engineering experience. Equivalent combination of education and work experience may be considered.

LANGUAGE SKILLS

Ability to read, analyze, and interpret prints, and foundry journals. Ability to respond to common inquiries or complaints from customers. Ability to effectively work with and present information to operators and top management.

MATHEMATICAL SKILLS

Ability to comprehend and apply principles of modern algebra, and statistics.

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to talk, hear, sit, stand, walk, and use hands and fingers to operate a computer keyboard, mouse, and/or telephone keypad. The employee is occasionally required to reach with hands and arms, taste or smell, and lift and/or move up to 100 pounds.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally exposed to fumes or airborne particles, wet and/or humid conditions, moving mechanical parts, toxic or corrosive chemicals, extreme cold, extreme heat, and risk of electrical shock. The noise level in the work environment is usually moderate.

Benefits:

Benefits include major medical (BCBS), Delta dental and vision, company sponsored basic life insurance and short-term disability. Voluntary life insurance, accidental death and dismemberment, and long-term disability available. Competitive 401(k) with company matching, generous PTO, 10 paid holidays, and company giveaways, family picnics, and more!

A pre-employment Background Check and 6 panel (no THC) Drug screen required

A.Y. McDonald Mfg. Co. is an equal opportunity employer

You will be required to work on-site at our Dickeyville, WI facility

Education

Preferred

- Bachelors or better in Engineering

Equal Opportunity Employer

This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.