Process Control Technician (10pm-6am)

Orion Castings; Town of Grafton (WI); On-site; USD 60,000 - 85,000; Full time

Benefits offered by this job

Sign-on bonus

Diversity commitment

Job summary

Orion Casting in Wisconsin is seeking a Process Control Technician to develop, monitor, and optimize high-pressure aluminum die casting processes, ensuring safe operation, consistent quality, and maximum productivity. You will work closely with production, tooling, maintenance, quality, and engineering to establish process standards, troubleshoot issues, and support continuous improvement initiatives.

The role includes setting up machines, analyzing process variables, initiating trials, and

Qualifications

• 2+ years in manufacturing environment, preferably die casting or related production processes.
• Knowledge of aluminum alloys and vacuum die casting (preferred).
• Familiar with IATF 16949 quality requirements.
• Experience with real-time process monitoring systems.
• Familiar with X-ray analysis of castings.
• Proficient in office software for communication, documentation, and reporting.

Responsibilities

• Develop and maintain standardized die casting process parameters.
• Set up and optimize die casting machines for new and existing production.
• Monitor critical process variables: melt temp, die temp, shot profiles, injection speeds, pressures, fill and cycle times, lubrication.
• Analyze casting defects and perform root cause analysis.
• Create and maintain process sheets and machine setup instructions.
• Collaborate with quality to improve first-pass yield and reduce scrap.
• Assist in die tryouts and new product launches; recommend improvements.
• Validate process changes through production trials; ensure compliance with specs.
• Train operators on approved process standards; participate in lean initiatives.

Skills

Analytical thinking

Troubleshooting

Communication

Teamwork

Data interpretation

Education

High school diploma or equivalent

Tools

X-ray analysis equipment

Die casting machines

Process data software

Job description

Join us in becoming the premier die casting manufacturer and engineering solutions supplier worldwide.

$1,700 Sign-On Bonus – $300 at 3 months, $500 at 9 months, and $900 at 12 months

_ Summary _

The Process Control Technician is responsible for developing, monitoring, and optimizing high-pressure aluminum die casting processes to ensure safe operation, consistent quality, and maximum productivity. This position works closely with production, tooling, maintenance, quality, and engineering to establish process standards, troubleshoot manufacturing issues, and support continuous improvement initiatives.

_ Principal Duties and Responsibilities _

(but not limited to…)

• Develop and maintain standardized die casting process parameters.
• Set up and optimize die casting machines for new and existing production.
• Monitor critical process variables including:
  • Melt temperature
  • Die temperature
  • Shot profiles
  • Injection speeds
  • Intensification pressure
  • Fill time
  • Cycle time
  • Lubrication parameters
• Analyze casting defects including:
  • Porosity
  • Cold shuts
  • Blisters
  • Flash
  • Soldering
  • Misruns
  • Shrinkage
• Perform root cause analysis using process data.
• Establish and maintain documented process sheets and machine setup instructions.
• Work with quality personnel to improve first-pass yield and reduce scrap.
• Assist in die tryouts and new product launches.
• Recommend tooling, process, or equipment improvements.
• Validate process changes through production trials.
• Ensure compliance with customer specifications and quality standards.
• Train operators and setup technicians on approved process standards.
• Participate in continuous improvement and lean manufacturing initiatives.

Please note that the duties and requirements described herein are intended to represent general contents of this job. This is not to be construed as an exhaustive statement of duties and responsibilities.

_ Qualifications _

• 2+ years of experience in a manufacturing or industrial environment, preferably in high-pressure aluminum die casting, casting operations, machining, maintenance, automation, or similar production processes.
• Strong understanding of:
  • Aluminum alloys
  • Vacuum die casting (preferred)
  • Thermal management
  • Die lubrication systems
  • Hydraulic systems
  • Robot automation
• Working knowledge of computer applications used for communication, documentation, and reporting
• Understanding of molding principles applied to die casting is a plus.
• Experience with real-time process monitoring systems.
• Familiarity with X-ray analysis of castings.
• Knowledge of IATF 16949 quality requirements.

_ Skills: _

• Strong analytical and troubleshooting skills.
• Ability to interpret production and quality data.
• Excellent communication and teamwork.
• Strong organizational skills and attention to detail.
• Ability to manage multiple priorities in a fast-paced manufacturing environment.

_ Key Position Competencies: _

• Communications – Listening, Reading Comprehension, Speaking and Writing.

• Cognition – Analysis/Reasoning, Creative & Innovative Thinking, Decision Making & Judgement, and Problem Solving.

• Personal Effectiveness – Accountability & Dependability, Adaptability & Flexibility, Customer Focus, Development & Continual Learning, Ethics & Integrity, Results Focus & Initiative, Safety Focus, Self-Management, Stress Tolerance, and Tact.

• Interaction with Others – Influencing Others, Relationship Building, Teamwork and Valuing Diversity

• Occupational – Advocating Causes, Enforcing Laws, Rules & Regulations, Facilitating Groups, Interviewing Others, Providing Consultation, and Presenting Information.

• Management Qualities – Business Alignment, Coaching and Mentoring, Leadership, Fiscal Accountability, Organizational & Political Savvy, Planning & Organizing, Staff Management and Strategic Vision.

For more information about Orion Casting Careers and future job postings, please JOIN our Talent Community at www.orioncastings.com/careers and follow us at:

Orion Casting has a strong commitment to the principle of diversity, and in that spirit seeks a broad spectrum of candidates including women, minorities, veterans, and people with disabilities. Individuals with disabilities desiring accommodations in the application process should notify the hiring department by the application deadline.