Process Engineer - Cast House

Hydro Extrusions; Phoenix (AZ); On-site; USD 95,000 - 120,000; Full time

Benefits offered by this job

Retirement Savings Plans with Company

Education Assistance

Bonus Plan Eligibility

Job summary

Hydro Cast House in Phoenix seeks a Process Engineer to optimize aluminum melting, alloying, casting, and related manufacturing processes to ensure safe, efficient, and cost-effective operations. You will drive technical support across operations, maintenance, quality, and HSE to improve performance and metal recovery.

You will partner with Operations and Engineering to identify opportunities, troubleshoot challenges, reduce scrap, and implement sustainable improvements aligning with Hydro's

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science, Mechanical Engineering, Chemical Engineering, or a related technical field required.
• 3–5 years of process engineering, manufacturing engineering, or related experience in an industrial manufacturing environment required.
• Must be English speaking, Spanish is a plus.

Responsibilities

• Analyze and optimize aluminum melting, holding, alloying, metal treatment, and casting processes to improve operational performance.
• Monitor and analyze critical process parameters, including furnace temperatures, melt rates, casting temperatures, cycle times, and metal chemistry, using production data to identify trends, improvement opportunities, and measurable results.
• Identify opportunities to improve metal recovery, reduce dross generation, minimize melt loss, reduce scrap and downtime, improve quality, and increase production efficiency.
• Develop, implement, and maintain standardized operating procedures and process control parameters.
• Evaluate process capability and identify improvements to increase casting consistency and billet quality.
• Provide technical support for furnace operations, casting equipment, molten metal transfer, and related processes.
• Support the introduction of new alloys, process technologies, and equipment improvements, including equipment installation, layout, startup, and process optimization activities.

Skills

Statistical process control (SPC)

Lean Manufacturing

Six Sigma

Kaizen

Cross-functional collaboration

Project management

Analytical skills

Education

Bachelor’s degree in Metallurgical Engineering / Materials Science / Mechanical Engineering / Chemical Engineering

Job description

Location: Phoenix, AZ, US, 85043 Career area: Engineering Department: Shift B Job Type: Permanent

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Hydro Extrusions is a world-leading aluminium extrusion business counting around 100 production sites in 40 countries and employing 20,000 people. Through our unique combination of local expertise, global network, and unmatched R&D capabilities, we can offer everything from standards profiles to advanced development and manufacturing for most industries. Since 1905, Hydro has turned natural resources into valuable products for people and businesses with focus on a safe and good workplace for our 30,000 employees in more than 140 locations.

What we offer you

• Retirement Savings Plans with Company Match/Contributions
• Education Assistance
• Bonus Plan Eligibility

Job Summary:

The Cast House Process Engineer is a dedicated engineering resource supporting process performance and continuous improvement within the Phoenix Cast House. The role is responsible for optimizing aluminum melting, alloying, casting, and related manufacturing processes to ensure safe, efficient, and cost-effective operations. This position provides technical expertise and engineering support to improve metal recovery, product quality, equipment reliability, and overall cast house performance.

The Process Engineer will partner closely with Operations, Maintenance, Quality, and HSE teams to identify process improvement opportunities, troubleshoot production challenges, reduce scrap, and implement sustainable solutions that support Hydro's operational excellence objectives.

This position plays a critical role in driving process stability, standardization, and continuous improvement while maintaining compliance with safety, environmental, and quality standards.

What you will be doing

Use manufacturing and process data to identify root causes, implement improvements, and evaluate whether changes are delivering sustainable improvements in quality, reliability, downtime, and throughput.

• Analyze and optimize aluminum melting, holding, alloying, metal treatment, and casting processes to improve operational performance.

Monitor and analyze critical process parameters, including furnace temperatures, melt rates, casting temperatures, cycle times, and metal chemistry, using production data to identify trends, improvement opportunities, and measurable results.

Identify opportunities to improve metal recovery, reduce dross generation, minimize melt loss,reduce scrap and downtime, improve quality, and increase production efficiency.

• Develop, implement, and maintain standardized operating procedures and process control parameters.
• Evaluate process capability and identify improvements to increase casting consistency and billet quality.
• Provide technical support for furnace operations, casting equipment, molten metal transfer, and related processes.

Support the introduction of new alloys, process technologies, and equipment improvements,including equipment installation, layout, startup, and process optimization activities.

What will make you successful?

Required Education/Experience:

• Bachelor’s degree in Metallurgical Engineering, Materials Science, Mechanical Engineering, Chemical Engineering, or a related technical field required.
• 3–5 years of process engineering, manufacturing engineering, or related experience in an industrial manufacturing environment required.
• Must be English speaking, Spanish is a plus.

Preferred Skills/Qualifications:

Working knowledge of industrial manufacturing equipment, including hydraulic and pneumatic systems, process controls, and manufacturing quality systems.

• Experience with statistical process control (SPC), process capability analysis, and manufacturing performance metrics.
• Experience with Lean Manufacturing, Six Sigma, Kaizen, and structured problem-solving tools.
• Knowledge of aluminum alloys, metallurgy, solidification, and casting defect prevention.
• Knowledge of ISO 9001, IATF 16949, and automotive manufacturing quality requirements.
• Experience supporting capital improvement projects, equipment installations, and process automation.
• Demonstrated experience in process optimization, root cause analysis, and continuous improvement.
• Strong analytical skills with the ability to interpret manufacturing data and implement measurable improvements.
• Strong communication, project management, and cross-functional collaboration skills.
• Ability to work in an industrial manufacturing environment and provide technical support across production shifts as needed.

Equal opportunities

Hydro in North America is an Equal Opportunity Employer where all phases of employment are based strictly upon the qualifications of the individual as related to the work requirements of the position. This policy is applied without regard to race, sex, sexual orientation, gender identity, religion, national origin, ancestry, age, disability, veteran status, marital status or any other category protected by law. We strive to provide equal opportunities for all to contribute and succeed with us.

As part of our recruitment process, we may use job‑related assessments in selected roles. These tools help us better understand work‑related strengths and support a fair and consistent hiring process. Any assessment results are reviewed together with your experience, qualifications, and interviews, and are never used as the sole basis for hiring decisions.

Are you looking to make a real impact? For over a century, our people have been the driving force in solving some of the world's most pressing issues - and we hope you'll join us in solving the next century's. Whether you're working to close the loop at one of our recycling facilities or ensuring efficient renewable energy processes to decarbonize aluminium production, your contributions make an impact in our shared purpose of propelling our industries and the world into a greener future.

About Hydro

• Hydro is a leading aluminium and renewable energy company committed to a sustainable future
• Founded: 1905
• Number of employees: 32,000
• Company presence in around 40 countries worldwide

A key part of succeeding in this mission involves encouraging a collegial environment where our differencesare acknowledged as our greatest competitive advantage. Your diverse perspective makes us stronger. Ourglobal diversity, inclusion and belonging program enables us to cultivate a high-performing and inclusiveworkplace where everyone feels valued.

Your career journey is unique. We strive to provide you with the support needed to achieve your full potential.With our global reach, inclusive culture, and cutting-edge technology you'll have the opportunity to build acareer that aligns with your strengths and passions. Join our global community of over 30,000 people with apresence in 40 countries and united by the values of Care, Courage and Collaboration. At Hydro, you havethe chance to make a difference in the industries that matter. Explore our world and the heart of our operations.