Casting Production Supervisor

Bharat Forge Aluminum USA, Inc.; Sanford (NC); On-site; USD 70,000 - 90,000; Full time

Job summary

Bharat Forge Aluminum USA, Inc. is seeking a Supervisor for their aluminum casting operations located in Sanford, North Carolina. The role requires supervision of casting processes, ensuring production efficiency while adhering to safety and quality standards.

The ideal candidate will have 3–5 years of experience in a manufacturing environment, strong leadership skills, and in-depth knowledge of aluminum casting processes. The position also involves monitoring equipment, managing teams, and implementing continuous improvement practices.

Qualifications

• Minimum 3–5 years of supervisory experience in aluminum casting or high-volume manufacturing.
• Strong understanding of aluminum melting and casting processes.
• Knowledge of casting defect analysis and corrective actions.

Responsibilities

• Supervise daily aluminum casting operations to ensure efficiency and safety.
• Monitor casting parameters and adjust operations as necessary.
• Lead production teams and coordinate maintenance activities.

Skills

Supervisory experience

Knowledge of aluminum casting processes

Strong leadership abilities

Communication skills

Lean Manufacturing knowledge

Education

Associate's or Bachelor's degree in Engineering or related field

Tools

ERP/MES systems

Job description

Description

Duties/Responsibilities

• Supervise daily aluminum casting operations, including melting, furnace operation, molten metal handling, casting, trimming, finishing, and material movement activities.
• Ensure production schedules are achieved while maintaining safety, quality, cost, and delivery targets.
• Monitor and control critical casting parameters such as melt temperature, metal chemistry, die temperatures, cycle times, and casting yields.
• Lead and support production teams operating casting cells, furnaces, robotic equipment, trimming presses, and finishing operations.
• Coordinate alloy changes, product changeovers, and startup activities to minimize downtime and maximize productivity.
• Work closely with Quality, Engineering, Maintenance, and Tooling departments to resolve casting defects, equipment issues, and process variations.
• Analyze and reduce casting defects including porosity, shrinkage, inclusions, cold shuts, misruns, and dimensional nonconformities.
• Drive continuous improvement initiatives focused on scrap reduction, yield improvement, cycle time optimization, and Overall Equipment Effectiveness (OEE).
• Ensure compliance with all foundry safety standards related to molten aluminum handling, lockout/tagout, confined space entry, PPE requirements, and environmental regulations.
• Monitor labor utilization, production performance, downtime events, and key manufacturing metrics; develop corrective action plans when targets are not achieved.
• Support implementation of Lean Manufacturing, 5S, TPM, and continuous improvement programs throughout the casting operation.
• Conduct daily production meetings and communicate plant goals, safety concerns, quality issues, and production priorities to team members.
• Develop and mentor employees through training, performance management, and succession planning activities.
• Coordinate preventive maintenance activities on furnaces, casting machines, conveyors, trimming equipment, and auxiliary systems to ensure equipment reliability.

Requirements

Required Skills/Abilities:

• Associate's or Bachelor's degree in Engineering, Manufacturing, Metallurgy, Industrial Technology, or related field preferred; equivalent experience considered.
• Minimum 3–5 years of supervisory experience in an aluminum casting, foundry, die casting, permanent mold, or high-volume manufacturing environment.
• Strong understanding of aluminum melting, casting processes, metal flow characteristics, and casting quality requirements.
• Experience managing furnace operations, molten metal safety procedures, and casting process controls.
• Knowledge of casting defect analysis, root cause investigation, corrective actions, and quality systems.
• Familiarity with automotive manufacturing standards, APQP, PFMEA, Control Plans, and IATF 16949 requirements preferred.
• Strong leadership, coaching, and team-building abilities in a fast-paced manufacturing environment.
• Experience utilizing ERP/MES systems and production reporting tools.
• Knowledge of Lean Manufacturing, Six Sigma, 5S, and continuous improvement methodologies.
• Ability to make sound decisions under pressure while balancing safety, quality, delivery, and cost objectives.
• Excellent communication, organizational, and problem-solving skills.

Physical Requirements:

• Ability to work in a high-temperature manufacturing environment with exposure to molten aluminum, furnaces, and industrial equipment.
• Ability to wear required personal protective equipment (PPE), including heat-resistant clothing, face shields, gloves, hearing protection, and safety footwear.
• Ability to stand and walk for extended periods throughout the production area.
• Ability to lift up to 35 pounds occasionally.
• Ability to climb stairs, ladders, platforms, and access elevated work areas.
• Ability to bend, squat, kneel, and reach during inspections and troubleshooting activities.