Manufacturing Engineer at PREMIER ALUMINUM – RACINE, Wisconsin

Position Summary:
The Foundry & Machining Manufacturing Engineer is responsible for designing, developing, and optimizing integrated manufacturing processes involving metal casting and precision CNC machining. This role ensures products meet stringent quality, efficiency, and cost-effectiveness standards by collaborating with project management, production, and quality control teams.

Key Responsibilities:

• Design & Development:
  • Collaborate with all departments to ensure new product designs are optimized for manufacturability (DFM).
  • Design and produce foundry tooling, patterns, and finishing work holding components using SolidWorks or other 3D CAD software.
  • Develop and implement gating and rigging designs, often utilizing casting simulation software (e.g., MAGMASOFT) to minimize defects.
• Foundry Operations:
  • Develop, evaluate, and improve foundry processes (molding, core room, melting, pouring, and cleaning) to increase productivity, reduce costs, and ensure quality.
  • Troubleshoot and resolve process issues in the foundry using root cause analysis and implementing corrective actions.
  • Apply metallurgy and materials science principles to understand the behavior of different metals and alloys during casting and heat treatment processes.
• Machining Operations:
  • Program, set up, and optimize CNC machining equipment (lathes, mills) to enhance throughput without compromising part quality.
  • Review engineering design drawings for compatibility with state-of-the-art machining techniques and implement process instructions.
  • Evaluate requirements for assembly tooling, fixtures, and gauging needed to support machining and finishing operations.
• Continuous Improvement & Quality:
  • Lead and participate in continuous improvement and Lean Manufacturing initiatives (e.g., Six Sigma, 5S, VSM) to eliminate waste and improve efficiency.
  • Assure product and process quality by designing testing methods, performing dimensional inspections, and analyzing data and trends.
  • Coordinate equipment maintenance and ensure compliance with all government laws and safety regulations.

Education: A Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Metallurgical Engineering, or a related field is preferred

• Experience: A minimum of 3-5 years of experience in foundry operations, precision machining, or a related manufacturing environment preferred
• Technical Skills:
  • Proficiency in 3D CAD software (SolidWorks, Creo, etc.) and CAM software (Mastercam, etc.).
  • Experience with process simulation software for metal casting is a plus.
  • Strong knowledge of GD&T (Geometric Dimensioning and Tolerancing) standards and their application.
• Soft Skills:
  • Excellent attendance.
  • Strong work ethic.
  • Detail oriented.
  • Deadline oriented.
  • Excellent problem-solving, analytical, and troubleshooting skills.
  • Strong project management skills with the ability to manage multiple projects simultaneously.
  • Effective communication and interpersonal skills, with the ability to work collaboratively in cross-functional teams.