Position Summary:
Tampa Brass & Aluminum Corp. is seeking a Foundry Engineer / Casting Specialist to support foundry operations on the night shift. This position combines technical foundry engineering, casting process development, production support, troubleshooting, and hands-on process improvement. The ideal candidate will have experience with metal casting, foundry processes, tooling, molds, melting, pouring, solidification, casting defects, and manufacturing process improvement. This individual will work closely with production, quality, engineering, maintenance, and management teams to ensure safe, efficient, and consistent casting operations. The successful candidate will be comfortable working directly on the production floor, troubleshooting casting and process issues, analyzing defects, and implementing practical solutions to improve quality, productivity, yield, and overall foundry performance.
Essential Responsibilities Foundry Engineering & Process Development:
Develop, evaluate, and improve casting processes for aluminum and other non-ferrous alloys.
Support the development and optimization of molds, patterns, cores, gating systems, risers, and related tooling.
Analyze casting designs and manufacturing requirements to identify potential production challenges.
Establish and improve process parameters for melting, pouring, molding, cooling, and finishing operations.
Assist with process trials, new product introductions, and production implementation.
Develop and maintain process documentation, work instructions, specifications, and standard operating procedures.
Use engineering principles and production data to identify opportunities for improved yield, quality, and efficiency.
Casting Troubleshooting & Defect Analysis:
Investigate casting defects including porosity, shrinkage, inclusions, cold shuts, misruns, cracks, dimensional issues, and surface defects.
Perform root-cause analysis and implement corrective and preventive actions.
Work with Quality personnel to identify defect trends and develop permanent solutions.
Evaluate rejected castings and determine appropriate disposition or rework requirements.
Monitor process conditions and make adjustments to prevent recurring defects.
Provide technical support to operators and supervisors when casting or production issues occur.
Production & Night Shift Support:
Provide engineering and technical support to foundry production during the night shift.
Monitor critical casting processes and ensure established parameters are followed.
Work directly with operators and production leadership to resolve process issues.
Assist with troubleshooting equipment, tooling, molds, and process-related problems.
Communicate significant production, quality, safety, and equipment issues to appropriate management and the incoming shift.
Ensure production activities remain aligned with customer specifications and established quality requirements.
Participate in shift handoffs and provide clear documentation of outstanding issues and corrective actions.
Continuous Improvement:
Identify opportunities to improve casting quality, production efficiency, material utilization, and overall yield.
Participate in Lean Manufacturing, Six Sigma, root-cause analysis, and continuous improvement initiatives.
Analyze scrap, rework, downtime, and production data to identify trends and improvement opportunities.
Recommend changes to processes, tooling, equipment, and work methods.
Support implementation and validation of process improvements.
Quality & Compliance:
Ensure foundry processes meet internal quality standards, customer requirements, and applicable specifications.
Work closely with Quality Engineering and Quality Control teams on nonconformances and corrective actions.
Assist with maintaining process control documentation and production records.
Support audits, customer requirements, and quality investigations as needed.
Follow all company safety policies and procedures.
Safety:
Promote a strong safety culture throughout the foundry.
Follow all applicable safety procedures related to molten metal, furnaces, molds, chemicals, equipment, PPE, and material handling.
Identify unsafe conditions and immediately communicate concerns to management.
Participate in safety investigations and corrective actions when required.
Qualifications:
Bachelor's degree in Metallurgical Engineering, Materials Engineering, Mechanical Engineering, Manufacturing Engineering, or a related field preferred.
Equivalent combination of education and hands-on foundry experience may be considered.
Experience in a metal casting, foundry, manufacturing, or related industrial environment.
Strong understanding of casting processes, metallurgy, mold design, gating/riser systems, and casting defects.
Experience troubleshooting casting and production problems.
Ability to interpret engineering drawings, specifications, and technical documentation.
Knowledge of GD&T and dimensional requirements is preferred.
Experience with root-cause analysis and corrective action methodologies.
Strong analytical and problem-solving skills.
Ability to work independently and make sound technical decisions during the night shift.
Strong communication and documentation skills.
Ability to work effectively with production operators, supervisors, quality personnel, engineers, and management.
Preferred Experience:
Experience with aluminum or non-ferrous metal casting.
Experience with permanent mold, sand casting, investment casting, or related casting processes.
Knowledge of melting and alloy control.
Experience with mold and tooling design.
Familiarity with casting simulation software is a plus.
Experience with Lean Manufacturing, Six Sigma, or continuous improvement methodologies.
Experience working in a high-volume manufacturing environment.
Previous experience supporting a night or off-shift production operation is highly preferred.
Physical & Work Environment:- This is a hands-on manufacturing position requiring regular presence on the foundry floor.
- Ability to work around heat, noise, industrial equipment, molten metal, dust, and manufacturing processes.
- Ability to wear required PPE, including safety shoes, eye protection, hearing protection, and other protective equipment.
- Ability to stand, walk, bend, reach, and move throughout the production environment for extended periods.
- Must be able to work the assigned night shift schedule and provide reliable off-shift technical support.
- Key Performance Areas
- Success in this position will be measured by:
- Casting quality and reduction of defects.
- Scrap and rework reduction.
- Improved casting yield and material utilization.
- Production efficiency and process stability.
- Timely resolution of technical and production issues.
- Successful implementation of process improvements.
- Accurate process documentation.
- Effective communication between shifts.
- Compliance with safety and quality requirements.
- Position TypeFull-Time | Night Shift | On-SiteThis position is ideal for a technically strong foundry professional who can combine engineering knowledge with hands-on casting expertise and independently support production during the night shift.
