Process Engineer

American Foundry Society; New Hampton (IA); On-site; USD 75,000 - 95,000; Full time

Job summary

ATEK Metal Technologies, part of Wisconsin Aluminum Foundry, seeks a Process Engineer in New Hampton, IA. You will own and develop manufacturing processes from design through validation, driving improvements that boost quality and efficiency on the shop floor.

You will lead CI initiatives, train operators, and collaborate with design engineering to resolve tooling issues, ensuring processes are controlled and audit-ready.

Qualifications

• 3+ years of foundry experience in low pressure aluminum casting.
• Experience solving molding problems in a foundry environment.
• Proven track record of reducing foundry process scrap.
• History of delivering continuous improvement projects.
• Willingness to work off-shift and weekends as needed.

Responsibilities

• Design and validate operating processes for new and existing products, ensuring they meet customer requirements, cycle time targets, and quality standards.
• Lead and deliver CI projects that reduce scrap, improve efficiency, and strengthen process control on the foundry floor.
• Own process-based problem solving in daily operations—identify root causes, implement fixes, prevent recurrence.
• Develop clear operating instructions to keep processes controlled, repeatable, and audit-ready.
• Partner with design engineering to resolve equipment and tooling issues before production impact.
• Educate and coach operators on proper procedures, building a culture of competence on the floor.
• Take full ownership of assigned processes under the Engineering Manager, driving urgent improvements.

Skills

Foundry experience

Process engineering

Molding problem solving

Continuous improvement

Shift flexibility

Job description

PROCESS ENGINEER
ATEK Metal Technologies — a Wisconsin Aluminum Foundry company | New Hampton, Iowa

Shape the systems that turn raw metal into precision. This is a hands‑on engineering role for someone who sees a problem on the floor and doesn't rest until it's solved.

THE OPPORTUNITY

At ATEK Metal Technologies, our process engineers don't just observe — they own. As our Process Engineer, you'll be responsible for developing, validating, and continuously improving the foundry processes that drive our quality and efficiency. From new product launches to day‑to‑day production support, your fingerprints will be on the work that matters most.

This role is for someone who leads from the front, operates with urgency, and takes genuine pride in making things run better than they did yesterday.

WHAT YOU'LL DO

Process Development & Validation — Design and validate operating processes for both new and existing products, ensuring they meet customer requirements, cycle time targets, and quality standards.

Continuous Improvement — Lead and deliver CI projects that reduce scrap, improve efficiency, and strengthen process control across the foundry floor.

Problem Resolution — Own process‑based problem solving in support of daily operations — identifying root causes, implementing fixes, and preventing recurrence.

Documentation & Standards — Develop clear, thorough operating instructions that keep processes controlled, repeatable, and audit‑ready.

Cross‑Functional Collaboration — Partner with design engineering to resolve equipment and tooling issues before they impact production.

Operator Training — Educate and coach process operators on proper procedures, building a culture of competence and accountability on the floor.

Process Ownership — Take full ownership of assigned processes under the Engineering Manager, driving execution and improvement with a sense of urgency.

QUALIFICATIONS

Required:

• 3+ years of foundry experience directly related to low pressure aluminum casting and process engineering


• Demonstrated experience in molding process problem solving in a foundry environment


• Experience reducing foundry process scrap


• Track record delivering continuous improvement projects


• Off-shift availability and flexibility to support 2nd or 3rd shift operations and weekends as needed

Preferred:

• Six Sigma methodology


• Foundry automation experience


• Experience in tooling, core make, and post‑molding processes (heat treatment, de-core, finishing)

Skills That Will Set You Apart:

• You don't wait to be told there's a problem — you find it first


• You can earn the trust of operators and engineers alike


• You hold yourself and others to a high standard, consistently and respectfully

WORK ENVIRONMENT

This is a foundry role. You'll spend significant time on the shop floor, where dust, heat, fumes, metal working fluids, and noise are part of the daily environment. Required PPE includes safety glasses, hearing protection, and steel‑toed footwear. Some desk time for documentation and programming tasks as needed.