Senior Process Control Technician – Die Cast Parameters & Defect Reduction

True North Consultants, Inc.; Cedarburg (WI); On-site; USD 51,000 - 85,000; Full time

Benefits offered by this job

401(k) with company match

Health/dental/vision benefits

Bonus PTO opportunities

Job summary

True North Consultants, Inc. seeks a Senior Process Control Technician for die casting. You will monitor high-pressure aluminum casting parameters, analyze defects, and drive first-pass yield on the 3rd shift in Cedarburg, WI. The role offers strong earnings, 401(k) matching, and full benefits.

You will troubleshoot complex defects, perform root-cause analyses, and help ensure tier-one OEM quality standards in an ISO-certified facility with long-tenured staff.

Qualifications

• Demonstrated career stability with 2+ years tenure at each prior employer.
• 2+ years of process control experience in manufacturing (aluminum die casting preferred).
• Strong problem-solving, data interpretation, and analytical skills.
• Must reside within a 45-minute commute of Cedarburg/Greater Milwaukee, WI area.
• High School Diploma or GED; technical degree preferred; US work authorization.

Responsibilities

• Monitor critical process parameters: melt temps, shot profiles, injection speeds, pressures, cycle times.
• Analyze and resolve casting defects: porosity, cold shuts, soldering, blisters, flash, misruns, shrinkage.
• Optimize machine parameters for new launches, trials, and existing runs.
• Maintain standardized process setup sheets and instructions for technicians and operators.
• Execute production trials with quality/engineering teams to improve first-pass yield and reduce scrap.
• Support quality and inspection: review real-time monitoring and X-ray data for specs.
• Train floor personnel on standardized parameters and practices.

Skills

Process control

Root-cause analysis

Data interpretation

Problem solving

Education

High school diploma

Tools

X-ray inspection

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.