Process Control Technician (6am-2pm)

Orion Castings; Town of Grafton (WI); On-site; USD 65,000 - 90,000; Full time

Job summary

Orion Casting in the United States seeks a Process Control Technician to develop, monitor, and optimize high-pressure aluminum die casting processes. You will work with production, tooling, maintenance, quality, and engineering to set standards, troubleshoot issues, and support continuous improvement initiatives.

You will set up machines, monitor process variables, perform root cause analysis, and train operators.

Qualifications

• 2+ years of experience in a manufacturing or industrial environment.
• Experience in high-pressure aluminum die casting, casting operations, machining, maintenance, automation, or similar production processes is preferred.
• Strong understanding of thermal management and hydraulic systems.
• 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.

Responsibilities

• Set up and optimize die casting machines for new and existing production.
• Monitor critical process variables including shot profiles, intensification pressure, fill time, cycle time, lubrication parameters, porosity, cold shuts, blisters, flash, soldering.
• 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 and validate 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.

Skills

Thermal management

Hydraulic systems

Process data analysis

Real-time monitoring

X-ray analysis

IATF 16949 knowledge

Communication

Teamwork

Job description

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…)

• Set up and optimize die casting machines for new and existing production.
• Monitor critical process variables including:
• Shot profiles
• Intensification pressure
• Fill time
• Cycle time
• Lubrication parameters
• Porosity
• Cold shuts
• Blisters
• Flash
• Soldering
• 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:
• Thermal management
• Hydraulic systems
• 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.
• 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.

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.