Senior Metallurgy & Process Leader (Casting)

Charter Casting; Woodstock (IL); On-site; USD 100,000 - 125,000; Full time

Benefits offered by this job

Health benefits

401(k) with matching and profitSharing

Life insurance

Paid time off

Job summary

Charter Casting in Woodstock, Illinois is seeking a Senior Process Metallurgist to provide technical leadership across Melt, Laboratory and Continuous Casting operations. You will apply metallurgy, materials science and manufacturing-process expertise to improve safety, quality, productivity and cost.

Working with Operations and cross-functional teams, you will troubleshoot complex issues, strengthen process controls, optimize practices, support new-product development and lead sustainable

Qualifications

• Bachelor’s degree in Metallurgical Engineering, Materials Science, or related field.
• 5+ years in metallurgical/materials/manufacturing/process engineering.
• Strong knowledge of metallurgy, materials science, cast iron manufacturing, process control and data analysis.
• Proven ability to lead cross-functional projects and influence outcomes.
• Experience with data analysis, DOE, DMAIC, and Lean tools.

Responsibilities

• Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices.
• Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release.
• Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance.
• Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables.
• Strengthen metallurgical quality and process consistency for gray and ductile cast iron products.
• Lead root cause analysis and implement sustained corrective actions for manufacturing and quality issues.

Skills

Metallurgical engineering

Process leadership

Data analysis

Root cause analysis

Cross-functional leadership

Lean principles

Statistical analysis

CAD/SolidWorks

Education

Bachelor’s degree in Metallurgical Engineering, Materials Science or related

Master’s degree (Nice to have)

Tools

SolidWorks

Microsoft Excel

ERP systems

MES

Job description

Charter Manufacturing is a fourth-generation family-owned business where our will to grow drives us to do it better. Join the team and become part of our family!

Charter Casting is hiring a Senior Process Metallurgist!

Alternative Job Titles: Senior Manufacturing Metallurgist, Lead Process Metallurgist, Senior Metallurgical Engineer

Job Summary

As a Senior Process Metallurgist, you will provide technical leadership with a strong focus on metallurgical and process engineering across the Melt, Laboratory, and Continuous Casting operations. You will apply materials science, metallurgy, and manufacturing-process expertise to improve safety, quality, productivity, and cost.

Partnering closely with Operations and cross-functional teams, you will troubleshoot complex technical issues, strengthen process controls and standards, optimize melting and casting practices, support new-product development, and implement sustainable process improvements. This role serves as a primary technical resource for manufacturing process performance and product quality.

Position Specifics

• Location: Woodstock, IL
• Schedule: Onsite
• Travel: Up to 10% travel
• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time.
  
  

Key Responsibilities

Metallurgical & Process Engineering Leadership

• Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices.
• Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release.
• Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance.
• Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables.
• Strengthen metallurgical quality and process consistency for gray and ductile cast iron products.
  
  

Process Optimization & Technical Problem Solving

• Partner with Operations to troubleshoot manufacturing, process, and quality issues; lead root cause analysis and implement sustainable corrective actions.
• Analyze manufacturing, laboratory, quality, and process data to identify trends, reduce manufacturing losses, improve yield, and strengthen process capability.
• Lead process improvement projects through data analysis, process validation, production trials, and implementation of sustainable improvements.
• Investigate and resolve quality problems identified during manufacturing or through customer returns, including defect and failure analysis.
• Apply process engineering and continuous-improvement tools, including Design of Experiments, statistical analysis, process mapping, DMAIC, root cause analysis, and Lean principles.
  
  

Technical Systems, Projects & Product Support

• Maintain MES process master data and provide technical support for manufacturing system enhancements, troubleshooting, and process optimization.
• Support capital projects involving manufacturing equipment, tooling, furnaces, holders, refractory systems, and process improvements.
• Serve as the primary technical resource for new-product quoting by evaluating manufacturing feasibility, process capability, and technical risk.
• Partner with Procurement in qualifying new suppliers and ensuring incoming raw materials meet required technical and quality standards.
• Support the development and qualification of new or improved products, materials, manufacturing technologies, and process capabilities.
  
  

Cross-Functional Collaboration & Technical Expertise

• Collaborate with Operations, Quality, Maintenance, Engineering, Supply Chain, Sales, and Technical Services to solve technical problems and support strategic initiatives.
• Support Commercial and Sales teams as a technical resource for customer application questions, quality concerns, processing recommendations, and product performance.
• Develop and maintain manufacturing standards, work instructions, operating procedures, and technical documentation.
• Share technical knowledge and mentor employees on metallurgy, materials science, process controls, manufacturing processes, and continuous-improvement practices.
• Support Environmental, Quality, and Safety Management Systems and ensure compliance with company policies and regulatory requirements.
  
  

What You’ll Need

• Bachelor’s Degree in Metallurgical Engineering, Materials Science, or a related engineering discipline.
• Five or more years of experience in a metallurgical, materials, manufacturing, or process engineering environment.
• Strong understanding of metallurgy, materials science, cast iron manufacturing, process control, and data analysis.
• Demonstrated success solving complex technical problems and improving manufacturing processes.
• Strong analytical, troubleshooting, root cause analysis, and problem-solving skills.
• Ability to lead cross-functional projects and influence others without direct authority.
• Strong verbal, written, and presentation skills.
• Experience with SolidWorks 2D/3D CAD software, or willingness to learn, to support tooling, equipment, and process improvements.
• Proficiency with Microsoft Office and manufacturing data analysis tools.
• Ability to manage multiple priorities in a fast-paced manufacturing environment.
• Demonstrated commitment to safety, quality, and continuous improvement.
• Willingness to travel up to 10%.
  
  

Nice To Haves

• Master’s Degree in Metallurgical Engineering, Materials Science, Engineering, Operations Management, or a related field.
• Experience with induction melting and production of gray and ductile cast iron.
• Experience with continuous casting operations and cast iron manufacturing.
• Experience with metallurgical laboratory equipment, including optical emission spectrometers and LECO analyzers.
• Experience in defect analysis, failure analysis, and customer-facing technical support.
• Experience developing new or improved products.
• Experience with ISO or Quality Management Systems.
• Experience with MES and ERP systems supporting manufacturing processes; Oracle ERP experience is a plus.
• Lean Manufacturing and/or Six Sigma Green Belt certification, or equivalent continuous-improvement experience.
• Experience leading or supporting capital improvement projects involving manufacturing equipment, tooling, furnaces, holders, or process improvements.
• Proficiency with statistical analysis, process mapping, and data visualization tools.
  
  

Take the next step in your career, apply today!

About Charter Casting

Charter Casting is a premier U.S. partner and casting supplier for precision-engineered iron solutions. We deliver large, complex iron castings and DuraBar®, the industry’s leading continuous cast iron bar, with the consistency and performance customers depend on.

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The annual hiring range for this position is: $100,000-$125,000. The actual base pay offered to the successful candidate will depend on various factors, including but not limited to job-related skills, experience, and qualifications. Compensation decisions are tailored to the unique circumstances of each position and candidate.

We offer comprehensive health, dental, and vision benefits, along with a 401(k) plan that includes employer matching and profit sharing. Additionally, we offer company-paid life insurance, disability coverage, and paid time off (PTO).