Process Engineer-2

Orion Castings; Town of Grafton (WI); On-site; USD 85,000 - 110,000; Full time

Job summary

Orion Castings is seeking an experienced HPDC Process Engineer in Wisconsin to develop and control high-quality casting processes that meet cycle time and cost targets.

You will optimize shot profiles, temperatures, and pressures, troubleshoot defects, and support die design, trials and new product launches. Strong problem-solving and Lean/Six Sigma skills are essential for continuous improvement.

Qualifications

• Experience in high-pressure diecasting processes.
• Knowledge of die design and tooling.
• Expertise in DOE and statistical analysis.
• Strong root-cause problem solving.
• Familiar with SPC, Cp/Cpk, and OEE.
• Lean manufacturing / Six Sigma background.

Responsibilities

• Develop, optimize, and maintain HPDC processes for quality, productivity, and cost.
• Establish and optimize shot profiles, injection speeds, pressures, temperatures, and cooling parameters.
• Troubleshoot casting defects including porosity, flash, cold shuts, misruns, soldering, shrinkage, and dimensional variation.
• Optimize cycle times, scrap rates, OEE, and material utilization.
• Support die design, die trials, and new product launches.
• Perform root-cause analysis and corrective actions using structured problem-solving methods.
• Develop and maintain process parameters, standards, and work instructions.
• Use SPC and process data to monitor and improve process stability.
• Work closely with Quality, Tooling, Maintenance, Production, and Controls Engineering.
• Support PPAP, capability studies, DOE, and continuous improvement activities.
• Ensure processes meet safety, quality, and customer requirements.

Skills

HPDC

Die design

Aluminum/Mg/Zn casting

Injection systems

Defect analysis

DOE & statistics

Root-cause analysis

Lean Six Sigma

SPC & OEE

Automation familiarity

Job description

Primary Responsibilities

• Develop, optimize, andmaintain HPDC processes for quality, productivity, and cost.
• Establishand optimize shot profiles, injectionspeeds, pressures, temperatures, and cooling parameters.
• Troubleshoot casting defectsincluding porosity, flash, coldshuts, misruns, soldering, shrinkage, and dimensionalvariation.
• Optimize cycle times, scraprates, OEE, andmaterial utilization.
• Support die design, dietrials, and newproduct launches.
• Perform root-cause analysisand corrective actions using structured problem-solving methods.
• Developand maintain process parameters, standards, and work instructions.
• Use SPC andprocess data tomonitor and improveprocess stability.
• Work closely with Quality, Tooling, Maintenance, Production, and ControlsEngineering.
• Support PPAP, capability studies, DOE, and continuousimprovement activities.
• Ensure processes meet safety, quality, andcustomer requirements.

Key Knowledge/Skills

• High-pressure diecasting
• Die design andtooling
• Aluminum/magnesium/zinc casting
• Injection systems andshot profiles
• Casting defectanalysis
• DOE and statisticalanalysis
• Root-cause/problem-solving methods
• LeanManufacturing / Six Sigma
• SPC, Cp/Cpk, OEE
• Familiarity with die-casting machines, furnaces, robotics, and automation

In one sentence:

A HPDC ProcessEngineer is responsiblefor developing and controllingthe casting processso the machineconsistently produces high-quality parts atthe required cycletime and cost.