Lead Foundry Process Engineer

1 week ago

Chattanooga, Tennessee, United States Mueller Co. LLC Full time

Company Overview: Mueller Company, a subsidiary of Mueller Water Products and a publicly traded entity (NYSE: MWA), stands as the premier manufacturer of flow control devices within the water and gas distribution sectors. We are recognized as North America's largest and sole full-line supplier of potable water distribution products.

Position Summary:

  • Accountable for the design and execution of methodologies and equipment aimed at enhancing processes and managing manufacturing expenses.
  • Deliver engineering and technical insights in No Bake foundry process operations, focusing on safety enhancements, productivity advancements, quality standard implementation, and minimizing scrap, non-conformities, and returns.
  • Work in close collaboration with tooling and pattern design teams to ensure efficient tool qualification and PPAP processes.

Key Responsibilities:

  • Assess manufacturing processes by leveraging knowledge of product design, production, assembly, tooling, and materials.
  • Guide junior engineers and foster their understanding of processes.
  • Assist in the development of the foundry strategic plan and oversee its execution.
  • Apply expertise in foundry processes and casting defects to identify and rectify non-conformities.
  • Employ problem-solving methodologies such as Six Sigma, 8D, and 5 Whys to drive continuous process improvements.
  • Create process documentation, training materials, and controls to guarantee product quality and consistency.
  • Conduct assessments related to machine guarding, ergonomics, and human factors.
  • Enhance manufacturing efficiency by analyzing and planning workflow, spatial requirements, and equipment layout.
  • Provide insights for manufacturing decision-making by calculating production, labor, and material costs, reviewing production schedules, and forecasting future needs.
  • Possess a functional understanding of CAD modeling and rigging geometry for tooling engineering.
  • Gather, analyze, and summarize data, information, and trends to prepare product and process reports while maintaining product and process data.
  • Implement new systems and procedures as designed.
  • Utilize FMEA, DFMEA, and DOE methodologies to promote continuous improvement in manufacturing and engineering processes.
  • Support equipment troubleshooting in collaboration with the maintenance team and external vendors.
  • Develop and mentor staff and technicians.
  • Maintain professional and technical expertise through educational workshops, professional publications, networking, and participation in relevant professional organizations.
  • Direct efforts to ensure compliance with all regulatory bodies, organizations, and government requirements in the execution of position responsibilities.

Position Requirements:

  • Bachelor's Degree in Mechanical Engineering, Industrial Engineering, Materials Science, or Metallurgy with a minimum of 8 years of experience in foundry operations.
  • Alternatively, 12+ years of relevant experience in foundry operations.
  • Proficient knowledge of melting, molding, core making, casting finishing, tooling, and other facets of foundry production.
  • Experience in collaboration with product design, tooling engineering, and quality assurance for product qualification and PPAP processes.
  • Experience in the development, justification, and management of capital project scopes.
  • Strong knowledge and experience in Lean manufacturing and Six Sigma tools.
  • Exceptional PC and systems knowledge and skills.
  • Excellent leadership, communication, and interpersonal skills with the ability to engage with all levels of employees, customers, and external professionals.
  • Familiarity with complex manufacturing scenarios, hardware specifications, quality standards, product development, CAD/CAM, and technical specifications.

Mueller is proud to be an Equal Opportunity Employer.

We do not discriminate based on race, religion, color, national origin, gender, sexual orientation, gender identity, disability, veteran status, or any other legally protected characteristic.

We encourage individuals with the necessary skills to consider this opportunity.

This job description is subject to modification at any time. This document does not limit management's right to prescribe or restrict the tasks or duties that may be assigned or reassigned.

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