Senior Process Metallurgist

Charter Automotive; Woodstock (IL); Hybrid; USD 100,000 - 125,000; Full time

Benefits offered by this job

Health benefits

401(k) with company matching

Life insurance

Paid time off

Job summary

Charter Casting, part of Charter Manufacturing, seeks a Senior Process Metallurgist to lead metallurgical and process engineering across melt, lab, and continuous casting. You will drive safety, quality, productivity, and cost improvements while mentoring teams and supporting new-product development.

The role is based onsite in Woodstock, IL, with up to 10% travel and no visa sponsorship. Requires 5+ years in metallurgy/ manufacturing with strong analytical skills.

Qualifications

• Requires a Bachelor’s in Metallurgical Engineering, Materials Science, or related field.
• 5+ years in metallurgical/manufacturing/process engineering environment.
• Strong metallurgy, materials science, and data-analysis background.
• Proven ability to lead cross-functional projects and solve complex problems.
• Travel up to 10% and onsite work in Woodstock, IL.

Responsibilities

• Provide metallurgical and process engineering leadership across melt, lab, and casting.
• Develop and implement standards, melt recipes, and process instructions.
• Lead root-cause analyses and sustainable corrective actions.
• Support capital projects and technical systems improvements.
• Collaborate with Operations, Quality, and Engineering to optimize performance.

Skills

Leadership

Metallurgical expertise

Data analysis

Root cause analysis

Cross-functional collaboration

Problem solving

Statistical analysis

Education

Bachelor's Degree in Metallurgical Engineering or Materials Science

Master's Degree (Nice to have)

Tools

SolidWorks

MS Office

MES/ERP knowledge (Oracle ERP a plus)

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.

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.

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).

OUR STORY

Charter Manufacturing is a family-owned group of diversified metals manufacturing businesses founded in 1936 and headquartered in Mequon, Wis. Our will to grow drives our success. It is fueled by a team of respected and dedicated employees committed to continuous improvement and an entrepreneurial spirit that thrives within the Charter family.

WE ARE INVESTED IN YOU

When you work at Charter Manufacturing you’re part of a four-generation family business. That means, you’re not just an employee, you’re one of our family members. We believe in mutual trust. Employees are respected and empowered to explore new and better ways to impact the success of the company. Employees, at every level, are valued for their motivation to deliver the best products and service. We are in this together. Charter has a thriving team environment. Part of being a family means we collaborate, learn, thrive and benefit – together. We are committed to your future. The forward thinking and enthusiasm from our team drives us to create resources and opportunities for employees to learn, develop and create their own future. We celebrate you. We are successful because of our employees — and their great work doesn’t go unnoticed. We recognize and reward our employees for their contributions. Visit our website to learn more about our family of companies. View our 2022 Sustainability Report. To review our data use practices, visit our Company Privacy Policy. View/Download Employment-related Notices: FMLA Poster E-Verify Participation Poster (English & Español) Right to Work Poster (English & Español)