Senior Process Engineer – Alloy Manufacturing

The candidate must be willing to live and work in the Darlington, SC area, be a US citizen or permanent resident visa holder (no sponsorships offered) and be able to travel between company locations as well as visit suppliers and customers.

Professional and Technical Expertise as well as Excellent Leadership and Communication Skills with the Ability to Blend in with the Current Team (which has a high level of cooperative working “chemistry”) are required to be proven prior to an employment offer being made.

Basic Job Duties (after fully integrated) may include some or all:

• Manages all technical aspects (including chemistry control, process yield, dimensional and surface requirements) of all melting and post‑melting processes, with emphasis on achieving in‑spec chemistry at the lowest cost/risk to the company, this includes both melting and refining (VOD/VCD) of materials in our process.
• Provides technically appropriate aim chemistry targets for all manufacturing specifications in conjunction with customer and industry standard mechanical property requirements, manufacturing process capability, cost considerations and customer expectations.
• Manages tramp/trace element control in raw materials and revert streams.
• Oversees and actively verifies the charge make‑up process including suitability of charge materials, charge calculation accuracy, and weigh‑up accuracy.
• Manages process control, process parameters and consumable materials for the Horizontal Caster operation.
• Supervises (via outside contractors) the machining of critical components for the Horizontal Caster mold assembly, shear and a variety of other critical machined components for the operation of both plants.
• Manages the PLC and HMI software for the entire facility, must have some familiarity with ladder logic. Experience and Training in controls software would be a plus.
• Problem solves with/for customers (Foundry and Wrought).
• Educates Customers on our processes, process controls and capabilities.
• Interacts with Customers on tours and other events/visits as required.
• Resolves and Corrects product returns, complaints and Customer concerns.
• Accountable for scrap reduction on a continuous basis.
• Accountable for process cost reduction on a continuous basis.
• Performs Process and QMS audits on a regular basis of the melting, refining, casting and post‑production operations.

Attributes of the Ideal Candidate (However, recent graduates may apply):

• Intelligent and Quick to Learn, Demonstrated Ability to Learn New Concepts and Adapt to New and Changing Work Environments.
• A bachelor's degree in Metallurgy/Material Science or Applied Engineering.
• 3-15 Years of Experience in Metallurgical Process Engineering Work.
• Must be a “hands on” and “interactive” person, who spends a minimum of 50% of their workday in the plant environment.
• Leadership and Management Skills that Include:

• Excellent motivational and interpersonal skills.
• Safety Training, Awareness and Safe Practice Implementation.
• A focus on Continuous Improvement in all aspects of the operation.
• Driving Positive Change in a Manufacturing Culture.
• Proven Cost Reduction and Cost Management Experiences.
• Managing technical and non‑technical direct reports in manufacturing.

• Basic metals production and refining.
• Quality Standards (AS9100, ISO‑9002, NADCAP and similar).
• Design and manufacturing of precision machined components, to include the use and operation of Solid Works design and modeling software. This also includes the ability to create, read and interpret GD&T information into fabricated components and the inspection of those finished pieces.
• Horizontal or Vertical continuous casting of Co, Ni and Fe based alloys.
• Wrought products, forging, reduction and/or rolling.
• Data collection, management and analysis for Process Control and Continuous Improvement Purposes.