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Foundry Process Improvement Engineer

2 months ago

Decatur, Illinois, United States voestalpine Railway Systems Nortrak LLC Full time
Job Description

Company Overview

voestalpine Railway Systems Nortrak LLC is a leading designer and manufacturer of special trackwork, with a legacy spanning 160 years. We operate across Canada, the US, and Mexico, prioritizing the well-being of our people, global mobility, and sustainability and innovation.

Job Summary

We are seeking a Foundry Process Improvement Engineer to join our team in Decatur, IL. This role will utilize lean manufacturing, process control, and foundry experience to drive continual improvement in the ductile and manganese foundry.

Key Responsibilities

  • Safety:
    • Comply with and enforce all Nortrak safety policies and regulations.
    • Participate in the development and review of job safety analyses, setup instructions, hazard analyses of new foundry equipment and processes, and resolution of assigned safety committee issues.
    • Review and approve foundry work instructions and PPE requirements to ensure safe operation.
    • Ensure that outside vendors adhere to plant safety regulations and that MSDS for new and existing materials are reviewed, approved, and filed.
  • Quality:
    • Perform 5S and Kaizen events and engage employees in the continuous improvement process.
    • Be responsible for helping develop, implement, maintain, and improve standard processes, quality systems, capacity planning, and scheduling systems.
    • Evaluate existing foundry processes and develop proposals for methods, equipment, layouts, and materials for cost reduction, quality, and process enhancement, and safety.
    • Plan and optimize material flow through effective utilization of foundry equipment capacity, supplier capabilities, and material lead time, as well as leveraging outside capacity as needed.
    • Prepare written graphical work instructions for production staff.
    • Evaluate multiple potential solutions to derive the optimum solution using different problem-solving techniques such as A3 or the 8D process.
    • Review foundry process control techniques to ensure measuring and recording techniques employed are accurate and that monitoring protocols are adequate to effectively control foundry processes and facilitate troubleshooting.
    • Manage process control data within QCS and effect process changes to reduce scrap rates and improve product quality.
    • Maintain an extensive knowledge of applicable quality standards and procedures. Establish, adhere to, audit, and enforce vendor quality procedures and specifications.
    • Rig new castings as well as improve rigging on current products. Provide input to the methods drawings in order to maintain legacy of successful rigging.
    • Design and carry out test trials targeting product, process, and quality improvement.
  • On-Time Delivery:
    • Develop key manufacturing strategies and concepts that enhance employee safety, ensure quality in manufacturing processes, increase part flow/production, and reduce production time and cost.
    • Collaborate with Production Planning to designate machine utilization.
    • Assist the engineering department in transitioning new designs into production.
    • Develop and implement plans to improve foundry productivity.
    • Ensure timely development and verification of moulding and rigging.
    • Manage relationships with internal/external customers and vendors; ensure appropriate communications prevent delays due to sourcing or delivery issues.
  • Cost:
    • Assist in the cost estimating and quote preparation of cast components.
    • Lead foundry process improvements.
    • Manage capital projects, including justification, specifications, negotiation of price and terms, and oversee successful implementation or installation.
    • Assist in maintenance, repair, and commissioning of equipment. Work with production personnel to identify enhanced facility designs/layouts, create and implement enhanced manufacturing processes, and recommend capital improvements projects that support annual company objectives.
    • Ensure timely development and verification of moulding and rigging.
    • Manage relationships with internal/external customers and vendors; ensure appropriate communications prevent delays due to sourcing or delivery issues.
  • People:
    • Must be able to work with vendors, plant, and maintenance personnel to design, modify, and install equipment and perform facility modification.
    • Must be able to work with production and maintenance personnel, vendors, and other Nortrak plant personnel in a team-oriented environment.
    • Works with Maintenance Department to identify/resolve any equipment issues/concerns.
    • Coach and mentor foundry technical and operating personnel.
  • Environmental:
    • Adhere to Nortrak's Environmental Procedures, Practices, and Policies.

Requirements

Education:

  • Bachelor's Degree in Manufacturing or Industrial Engineering or other technical discipline.
  • Minimum of 5+ years of manufacturing-related experience, exposure to foundry is an asset.

Experience:

  • Experience with low volume/high component mix environment. Ability to troubleshoot foundry processes at the shop level.
  • Understanding of lean methodologies.
  • Strong knowledge of cost analysis, work simplifications, and value stream analysis.
  • Proven experience with foundry equipment capacity planning. Advanced Excel, Word, and Power Point skills.
  • Excellent written and verbal communication skills.

Physical Demands:

  • Prolonged periods of sitting at a desk and working on a computer.
  • Occasional standing, walking, stooping, kneeling, crouching, or climbing.
  • Must be able to lift or handle up to 25 pounds at times.
  • Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.
  • Occasional travel may be required, which includes walking, standing, sitting, and driving from short to long periods of time.

Benefits:

  • A supportive, family-oriented Nortrak Blue culture.
  • We provide an environment where Health and Safety is our #1 priority.
  • Career development opportunities and competitive pay progression.
  • Competitive medical, dental, and vision benefits.
  • Company-paid life and disability insurance.
  • Paid holidays and vacation.
  • Retirement plan with matching contributions.
  • Tuition Assistance Program.
  • Wellness Program.
  • Employee Assistance Program.
  • Employee Recognition Programs.