Overnight Lead Die Casting Technician

Sterling St James LLC; Cedarburg (WI); On-site; USD 47,000 - 66,000; Full time

Job summary

Sterling St James Inc. in Cedarburg, WI, is seeking a 3rd Shift Senior Process Control Technician for a high-volume aluminum die casting operation. You will monitor and optimize critical process parameters to reduce scrap and ensure OEM quality standards.

The ideal candidate will perform root-cause analysis, analyze X-ray data, and contribute to continuous improvement on the 3rd shift, with competitive pay up to $41 per hour plus benefits and 401(k) match.

Qualifications

• Minimum 2+ years at each previous employer.
• 2+ years in process control within a manufacturing environment.
• Must reside within 45-minute commute of Cedarburg, WI.
• High School Diploma or GED required; technical degree preferred; US work authorization.

Responsibilities

• Monitor and optimize process parameters (melt temps, shot profiles, injection speeds, pressures, cycle times, lubrication).
• Perform root-cause analysis on defects (porosity, cold shuts, soldering).
• Review X-ray data and maximize first-pass yield.
• Set up and validate die casting process parameters for launches and existing runs.
• Train operators on standardized parameters and procedures.

Skills

Process control

Root-cause analysis

Data interpretation

Troubleshooting

Process optimization

Education

High School Diploma or GED

Technical diploma or vocational degree in manufacturing technology or metallurgy

Tools

X-ray inspection data

Real-time process monitoring systems

Job description

3rd Shift Senior Process Control Technician – Cold-Chamber Die Casting

Up to $41.00/hr ($85,280/yr) + 401(k) Match & Bonuses Cedarburg, WI Area 3rd 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 3rd Shift schedule providing steady night-shift routine stability in a high-volume precision manufacturing setting.
• 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: Monitor and optimize high-pressure aluminum die casting process parameters (shot profiles, melt temps, intensification pressures), perform root-cause defect analysis (porosity, cold shuts, soldering), review X-ray data, and maximize first-pass yield.
• Strict Requirements & Authorization: Requires strict career stability (minimum 2+ years per employer), 2+ years of process control or technical troubleshooting experience in manufacturing, US work authorization, and a local commute within 45 minutes of Cedarburg, WI.

A premier, North American market leader in high-precision die casting is seeking a driven Process Control Technician to oversee and optimize process integrity on their 3rd shift production floor. Responsible for monitoring critical variables on automated, high-pressure aluminum casting cells, this seat plays a direct role in driving down scrap, troubleshooting complex part defects, and ensuring strict compliance with tier-one OEM quality standards.

Joining an ISO-certified facility where 40% of the team boasts over a decade of tenure, this direct-hire position offers outstanding hourly earnings, long-term stability, strong 401(k) matching, and structured career advancement opportunities in a supportive, team-first environment.

What You Will Be Doing (Daily Responsibilities)

• Monitor Process Parameters: Continuously track and analyze critical variables including melt temperatures, shot profiles, injection speeds, intensification pressures, cycle times, and die lubrication.
• Analyze & Resolve Casting Defects: Perform root-cause analysis on defect issues such as porosity, cold shuts, soldering, blisters, flash, misruns, and thermal shrinkage.
• Optimize Machine Parameters: Set up, fine-tune, and validate die casting process parameters for new product launches, die tryouts, and existing production runs.
• Maintain Process Standardization: Establish, document, and maintain accurate process setup sheets and operating instructions for setup techs and machine operators.
• Execute Production Trials: Collaborate with quality and engineering teams to validate process changes, improve first-pass yield, and minimize scrap rates.
• Support Quality & Inspection: Utilize real-time process monitoring systems and review X-ray inspection data to ensure parts meet customer specifications.
• Train Floor Personnel: Coach and train machine operators and setup technicians on standardized process parameters and operational best practices.

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.
• Manufacturing Process Experience: 2+ years of hands-on experience in process control within a manufacturing environment (aluminum die casting, plastic injection molding, or metalworking preferred).
• Technical & Analytical Aptitude: Strong problem-solving skills with the ability to interpret process monitoring data, thermal profiles, and quality reports.
• 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 diploma or vocational degree in manufacturing technology or metallurgy preferred. Must be fully authorized to work in the United States without sponsorship.

Preferred Technical Assets (Bonus Skills)

• Die Cast & Vacuum Systems: Specialized background in high-pressure aluminum die casting, vacuum-assisted die casting, or molten metal thermal management.
• Automation & Quality Standards: Familiarity with robotic automation, real-time shot monitoring software, X-ray inspection analysis, and IATF 16949 quality guidelines.
• Lean & Continuous Improvement: Practical experience with Six Sigma methodology, 5S, Pareto analysis, or formal root-cause analysis frameworks.