Senior Process Control Technician – Die Cast Parameters & Defect Reduction

RON SUNSHINE ASSOCIATES LLC; Cedarburg (WI); On-site; USD 51,000 - 85,000; Full time

Benefits offered by this job

Health, dental, vision benefits

401(k) with company match

Bonus opportunities

Job summary

Top Echelon LLC in Cedarburg, WI is seeking a Senior Process Control Technician for die casting. You will monitor and optimize high-pressure aluminum casting parameters on the 3rd shift to drive down scrap and improve first-pass yields.

Requires at least 2 years in process control in manufacturing, US work authorization, and a 45-minute commute to Cedarburg. The company offers competitive hourly wages up to $41/hour, full benefits, and 401(k) matching.

Qualifications

• Minimum 2+ years of tenure at each previous employer.
• 2+ years in process control within a manufacturing environment.
• Strong analytical skills and ability to interpret process data.
• Must reside within a 45-minute commute of Cedarburg, WI.
• U.S. work authorization; no sponsorship required.
• High School Diploma or GED; technical diploma preferred.

Responsibilities

• Monitor and optimize die casting process parameters (melt temp, injection speeds, cycle times).
• Perform root-cause analysis on defects (porosity, cold shuts, soldering, etc.).
• Set up and tune machine parameters for new launches and existing runs.
• Create and maintain process setup sheets and instructions.
• Conduct production trials with QA/engineering to improve first-pass yield.
• Utilize real-time monitoring and review X-ray data to meet specs.
• Train operators on standardized parameters and best practices.

Skills

Process control

Manufacturing

Root-cause analysis

Data interpretation

Quality monitoring

Education

High School Diploma or GED

Technical diploma or vocational degree in manufacturing technology or metallurgy

Tools

X-ray inspection software

Robotic automation

Job description

Senior Process Control Technician - Die Cast Parameters & Defect Reduction

Up to $41.00/hr ($85,280/yr) Cedarburg, WI Area 3rd Shift Direct-Hire / Full-Time

• Compensation & Earnings: Starting pay up to $41.00/hr ($85,280/yr baseline depending on experience), pay-for-performance bonus opportunities, 401(k) with company match, and full health/dental/vision benefits.
• Schedule & Work-Life Balance: Dedicated 3rd shift schedule with opportunities to earn additional hours of bonus PTO per year for strong attendance.
• Work Environment & Company Profile: Join one of the largest independent die casting manufacturers in North America featuring exceptional stability, 40% employee tenure over 10+ years, and premier tier-one OEM partnerships.
• Core Functional Scope: Monitor and optimize high-pressure aluminum die casting process parameters, conduct root-cause analysis on casting defects, and maximize first-pass yields.
• Strict Requirements & Authorization: Strict job stability required (minimum 2+ years per employer); 2+ years of process control or technical troubleshooting in manufacturing; local commute within 45 minutes of Cedarburg, WI; U.S. work authorization.

A premier, North American market leader in high-precision die casting is seeking a driven Process Control Technician to oversee and optimize process integrity on their 3rd shift production floor. Responsible for monitoring critical variables on automated, high-pressure aluminum casting cells, this seat plays a direct role in driving down scrap, troubleshooting complex part defects, and ensuring strict compliance with tier-one OEM quality standards. Joining an ISO-certified facility where 40% of the team boasts over a decade of tenure, this direct-hire position offers outstanding hourly earnings, long-term stability, strong 401(k) matching, and structured career advancement opportunities.

What You Will Be Doing (Daily Responsibilities)

• Monitor Process Parameters: Continuously track and analyze critical variables including melt temperatures, shot profiles, injection speeds, intensification pressures, cycle times, and die lubrication.
• Analyze & Resolve Casting Defects: Perform root-cause analysis on defect issues such as porosity, cold shuts, soldering, blisters, flash, misruns, and thermal shrinkage.
• Optimize Machine Parameters: Set up, fine-tune, and validate die casting process parameters for new product launches, die tryouts, and existing production runs.
• Maintain Process Standardization: Establish, document, and maintain accurate process setup sheets and operating instructions for setup techs and machine operators.
• Execute Production Trials: Collaborate with quality and engineering teams to validate process changes, improve first-pass yield, and minimize scrap rates.
• Support Quality & Inspection: Utilize real-time process monitoring systems and review X-ray inspection data to ensure parts meet customer specifications.
• Train Floor Personnel: Coach and train machine operators and setup technicians on standardized process parameters and operational best practices.

What We Are Looking For (Requirements & Qualifications)

• Job Stability Required: Demonstrated career stability with a strict requirement of at least 2+ years of tenure at each previous employer.
• Manufacturing Process Experience: 2+ years of hands-on experience in process control within a manufacturing environment (aluminum die casting, plastic injection molding, or metalworking preferred).
• Technical & Analytical Aptitude: Strong problem-solving skills with the ability to interpret process monitoring data, thermal profiles, and quality reports.
• Commutable Radius: Must reside within a 45-minute maximum commute of the Cedarburg / Greater Milwaukee, WI area.
• Education & Authorization: High School Diploma or GED required; technical diploma or vocational degree in manufacturing technology or metallurgy preferred. Must be fully authorized to work in the United States without sponsorship.

Preferred Technical Assets (Bonus Skills)

• Die Cast & Vacuum Systems: Specialized background in high-pressure aluminum die casting, vacuum-assisted die casting, or molten metal thermal management.
• Automation & Quality Standards: Familiarity with robotic automation, real-time shot monitoring software, X-ray inspection analysis, and IATF 16949 quality guidelines.
• Lean & Continuous Improvement: Practical experience with Six Sigma methodology, 5S, Pareto analysis, or formal root-cause analysis frameworks.