Process Engineer - High Pressure Die Cast (HPDC)

Mercury Marine; Fond du Lac (WI); On-site; USD 74,000 - 106,000; Full time

Benefits offered by this job

Annual discretionary bonus

401k match

Health Savings Account

Medical, dental, vision benefits

Paid vacation

Product purchase discounts

Job summary

Mercury Marine, based in Fond du Lac, Wisconsin, is seeking an HPDC Foundry Process Engineer to lead the die casting process in Plant 17. You will own metal delivery, tooling integration, and data-driven improvements to meet quality, cost, and safety goals.

You will collaborate with controls, maintenance, quality, tooling, and operations while advancing traceability and manufacturing data systems. A strong foundry background and continuous improvement mindset are essential.

Qualifications

• Must be hands-on on the shop floor in a foundry environment.
• Willingness to push the envelope with new processes and technologies.
• Strong cross-functional collaboration and communication skills.
• Ability to make independent, data-driven decisions backed by logic.
• Excel in a fast-paced manufacturing environment with moderate supervision.
• Apply systems thinking to consider all plant factors when solving problems.
• Self-driven to grow professionally through training and certifications.

Responsibilities

• Own and control the HPDC process including metal delivery and die tooling.
• Monitor and analyze process data to improve capability and quality.
• Lead continuous improvement on quality, uptime, cost, and safety.
• Collaborate with controls, maintenance, quality, tooling, and operations teams.
• Support traceability, in-process inspection, and data collection systems.
• Lead DF M recommendations and initial casting trials for new tooling.

Skills

Hands-on foundry

Cross-functional collaboration

Data-driven decisions

Systems thinking

Adaptability

Self-motivated

Continuous improvement

Education

Bachelor’s Degree in Manufacturing, Mechanical, Electrical or Controls Engineering

Tools

Allen-Bradley PLCs

ABB robotics

Excel

PowerBI

SQL Management Studio

SharePoint

Teams

Planner

CoPilot

MagmaSoft HPDC

Job description

Are you ready for what’s next?

Come explore opportunities within Brunswick, a global marine leader committed to challenging conventions and innovating next-generation technologies that transform experiences on the water and beyond. Brunswick believes “Next Never Rests™,” and we offer a variety of exciting careers and growth opportunities within united teams defining the future of marine recreation.

Innovation is the heart of Brunswick. See how your contributions will help transform vision into reality:

Position Overview

As part of the talented Plant 17 Engineering team, you will serve as a key technical leader within Mercury’s Aluminum HPDC Foundry (Plant 17), accountable for developing, controlling, optimizing, and sustaining the die casting process to meet quality, cost, delivery, and safety objectives.

Location: Plant 17

Workplace Category: Onsite

Travel Required: 5%

Direct Reports: 0

Pay Range: $73,600 to $106,200

Visa Sponsorship: Applicants must be currently authorized to work in the United States. This position is not eligible for employment visa sponsorship now or in the future.

Relocation: This position is not eligible for relocation assistance.

Essential Functions

• Own and control the HPDC process including metal delivery, shot profile development, die thermal management, spray and extraction cycles, part removal, trimming, and secondary operations
• Monitor, analyze, and interpret process and production data to understand parameter interactions, improve process capability, prevent defects, and ensure consistent casting quality
• Lead continuous improvement initiatives focused on quality, process stability, machine uptime, cost reduction, and safety through structured problem solving and standardization
• Serve as the casting process technical expert when collaborating with controls engineers, maintenance, quality, tooling, and operations teams
• Lead and support advancements in part traceability, in‑process inspection, and manufacturing data collection systems
• Support the successful launch of new tooling by providing Design for Manufacturing (DFM) recommendations and leading effective initial casting trials
• Limited part family and back-up responsibilities

Diversity of thought and experiences is fundamental when imagining the unimaginable. Certain skillsets/experiences are necessary; however, others can be developed along the way.

Required Qualifications

• Desire to be “hands on” at the shop-floor level within a foundry environment
• Willingness to “push the envelope” and try new processes, systems, & technologies that may be new to the foundry
• Strong cross-functional collaboration & communication skills with support teams and operations management
• Ability to make independent, data-driven decisions supported by sound logic
• Excel in a fast-paced, constantly changing manufacturing environment while working effectively with moderate supervision
• Apply a “systems” approach and look at all factors of the plant when solving problems and making improvements
• Self-driven to grow professionally through training, involvement in professional organizations, continuous education, and certifications

Preferred Qualifications

• Bachelor’s Degree in Manufacturing, Mechanical, Electrical or Controls Engineering or related engineering degree
• 3+ years of experience working in a foundry with direct responsibility controlling process related parameters
• Proven capability in applying casting process simulation to optimize processes and reduce defects
• Proficient with PLC’s, industrial controls, and robotics (specifically Allen Bradley and ABB)
• Strong knowledge of Microsoft Applications including Excel, Access, SQL Management Studio, Teams, SharePoint, Planner, CoPilot and PowerBI
• Experience utilizing and providing direction of shop floor dashboards
• Green Belt Certification with demonstrated success in applying Lean Manufacturing and Six Sigma methodologies to solve problems
• Ability to work with large amounts of data quickly and efficiently to uncover solutions
• Highly engaged contributor for PFMEA & control plan discussions
• Casting simulation software utilization with a preference to MagmaSoft - HPDC module

Working Conditions

• This position works in a foundry environment

The hiring range for this position is $73,600 to $106,200 annually. The actual base pay offered will vary based on multiple factors including job-related knowledge/skills, relevant experience, business needs, and geographic location. Compensation decisions are dependent upon the specifics of the candidate’s qualifications and the business context.

In addition to base pay, this position is eligible for an annual discretionary bonus. This position is eligible to participate in Brunswick's comprehensive and high-quality benefits offerings, including medical, dental, vision, paid vacation, 401k (up to 4% match), Health Savings Account (with company contribution), well-being program, product purchase discounts and much more. Details about our benefits can be found here.

Why Brunswick

Whatever tomorrow brings, we’ll be at the leading edge. As the clear leader in the marine industry, we’re committed to our values and supporting our exceptional people. We offer and encourage growth opportunities within and across our many brands. In addition, we’re proud of being recognized for making a splash with numerous awards!

About Mercury Marine

Headquartered in Fond du Lac, Wisconsin, Mercury Marine® is the world’s leading manufacturer of recreational marine propulsion engines. A division of Brunswick Corporation (NYSE: BC), Mercury provides engines, boats, services and parts for recreational, commercial and government marine applications. Mercury empowers boaters with products that are easy to use, extremely reliable and backed by the most dedicated customer support in the world. The company’s industry-leading brand portfolio includes Mercury outboard engines, Mercury MerCruiser® sterndrive and inboard packages, Mercury propellers, Mercury inflatable boats, Mercury SmartCraft® electronics, Land 'N' Sea marine parts distribution and Mercury and Quicksilver® parts and oils. More information is available at MercuryMarine.com.

Next is Now!

We value growth and development, recognizing that people come with a wealth of experience and talent beyond just the technical requirements of a job.

Brunswick is an Equal Opportunity Employer and considers all qualified applicants for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status or any other characteristic protected by federal, state, or local law. Diversity of experience and skills combined with passion is key to innovation and inspiration and we encourage individuals from all backgrounds to apply. If you require accommodation during the application or interview process, please contact [e-mail] for support.

Brunswick Corporation participates in E-Verify as part of our commitment to a lawful and transparent hiring process.