Die Cast Changeover Specialist – High-Pressure AL & Hydraulics (2nd Shift)

Calqulate; Cedarburg (WI); On-site; USD 47,000 - 66,000; Full time

Benefits offered by this job

401(k) Match

Bonuses

Health/dental/vision benefits

Attendance PTO bonus hours

Job summary

Calqulate is seeking a Die Cast Changeover Specialist for the 2nd shift in Cedarburg, WI. You will lead complete die changes and set machine parameters on high-pressure aluminum die casting equipment, ensuring quality and efficiency.

Work includes rigging tooling, troubleshooting hydraulics/pneumatics, and coordinating with Quality for first-piece inspections. Competitive benefits and a strong team culture are offered.

Qualifications

• 2+ years of tenure at each previous employer.
• Hands-on die casting setup or changeover experience.
• Strong mechanical troubleshooting in hydraulics, pneumatics, and related systems.
• Must be within a 45-minute commute of Cedarburg, WI; US work authorized.

Responsibilities

• Execute die changes and tooling setups for high-pressure aluminum die casting machines.
• Set and tune process parameters: melt temperatures, pressures, speeds, and cycle timing.
• Install dies, trim tools, and related tooling with proper rigging methods.
• Troubleshoot setup, machine, and casting defects to optimize cycles and reduce scrap.
• Inspect hydraulic, pneumatic, cooling, and lubrication systems prior to production sign-off.
• Coordinate with Quality for first-piece inspections and setup sheet adherence.
• Enforce safety standards including LOTO and crane safety during setups and teardowns.

Skills

Troubleshooting

Mechanical aptitude

Process parameter setting

Reading setup sheets

Safety compliance

Education

High School Diploma or GED

Tools

Overhead bridge cranes

Forklifts

Rigging equipment

Job description

Die Cast Changeover Specialist – High-Pressure Aluminum & Hydraulics (2nd Shift)

Up to $41.00/hr ($85,280/yr) + 401(k) Match & Bonuses Cedarburg, WI Area 2nd Shift Direct-Hire

• Pay & Incentives: Baseline starting pay up to $41.00/hr ($85,280/yr baseline scaling directly with experience) + pay-for-performance bonus opportunities, 401(k) with company match, full health/dental/vision benefits, and attendance PTO bonus hours.
• Work Pattern/Schedule: Dedicated 2nd Shift schedule providing consistent evening routine stability in a high-volume production environment.
• Environment & Company Profile: Direct-hire seat with one of North America's largest independent die casting manufacturers; ISO-certified facility featuring exceptional employee stability (40% of staff over 10+ years tenure) and premier tier-one OEM partnerships.
• Core Functional Scope: Lead complete die changes, set machine process parameters (shot speeds, melt temps, intensification rates), rig tooling, and troubleshoot hydraulic, pneumatic, and automation systems on high-pressure cold-chamber aluminum die casting equipment.
• Strict Requirements & Authorization: Requires strict career stability (minimum 2+ years per employer), hands-on die cast setup or heavy machinery changeover experience, mechanical troubleshooting depth, US work authorization, and a commute within 45 minutes of Cedarburg, WI.

A premier, North American market leader in high-precision die casting is seeking a skilled Die Cast Setup Technician to join their 2nd shift team. Operating in a fast-paced, high-volume production environment, this seat is critical for performing timely die changes, setting precise process parameters, and optimizing machine performance across high-pressure aluminum die casting cells.

Joining an ISO-certified facility where 40% of the workforce boasts over a decade of tenure, this direct-hire position offers long-term stability, competitive top-tier hourly pay, strong 401(k) matching, and clear career growth paths in an employee-centric workplace.

What You Will Be Doing (Daily Responsibilities)

• Execute Die Changes & Setups: Perform complete die changes and tooling setups for high-pressure aluminum die casting machines and auxiliary automation equipment.
• Set Process Parameters: Establish and fine-tune critical machine parameters including melt temperatures, hydraulic pressures, shot speeds, intensification rates, and cycle timing.
• Install Tooling & Auxiliaries: Safely rig, align, and install dies, trim tools, shot-end components, plunger systems, and cooling/lubrication lines using overhead cranes and forklifts.
• Troubleshoot Process & Quality: Diagnose and resolve setup, machine, or casting defects during startup and production runs to optimize cycle times and eliminate scrap.
• Verify System Functionality: Inspect hydraulic, pneumatic, water/cooling, and automated spray/ladle systems prior to production sign-off.
• Conduct First-Piece Inspections: Coordinate with Quality and Production to complete initial part runs and first-piece inspection approvals according to setup sheets.
• Enforce Safety Standards: Rigorously follow Lockout/Tagout (LOTO), crane safety protocols, and safe molten metal handling procedures during all setups and teardowns.

What We Are Looking For (Requirements & Qualifications)

• Job Stability Required: Demonstrated career stability with a strict requirement of at least 2+ years of tenure at each previous employer.
• Setup & Tooling Experience: Proven hands-on setup or changeover experience in high-pressure aluminum die casting, plastic injection molding, stamping, or heavy industrial manufacturing.
• Technical & Mechanical Aptitude: Strong troubleshooting capabilities in mechanical systems, hydraulics, pneumatics, and reading complex process setup sheets.
• Equipment Operations: Demonstrated ability to safely operate overhead bridge cranes, forklifts, and heavy rigging equipment.
• Commutable Radius: Must reside within a 45-minute maximum commute of the Cedarburg / Greater Milwaukee, WI area.
• Education & Authorization: High School Diploma or GED required; technical/vocational training preferred. Must be fully authorized to work in the United States without sponsorship.

Preferred Technical Assets (Bonus Skills)

• Cold-Chamber Aluminum Expertise: Specialized hands-on experience setting up cold-chamber die casting machines and automated robotic cells (ABB, FANUC).
• Defect Troubleshooting: Advanced knowledge of identifying and resolving porosity, cold shuts, soldering, and flash defects.
• Lean & Continuous Improvement: Practical experience utilizing 5S, SMED (Single-Minute Exchange of Die), or continuous improvement tools to reduce setup changeover times.