Foundry Engineer

Baker Manufacturing Company

Job Description

Job Title: Foundry Engineer
Department: Quality
Reports To: Quality Manager
FLSA Status: Exempt Salary
Schedule: 1st Shift, Monday Thursday, 5:00 a.m. 4:00 p.m. (1-hour lunch)

Position Summary

The Foundry Engineer is responsible for driving continuous improvement in cast part quality and process efficiency across the foundry. This role focuses on tooling evaluation, gating and riser design, pilot program management, and root cause analysis of casting defects. The Foundry Engineer partners with Quality, Production, and Metallurgy teams to identify process issues, validate solutions through testing, and implement permanent improvements. Occasional audits and operator training are also expected.

Key Responsibilities

Daily Responsibilities

• Analyze foundry scrap reports; identify trends and prioritize root cause follow-up.
• Review and initiate work orders for improvement of pattern/core box tooling.
• Support production teams by troubleshooting casting issues on the floor.
• Maintain and update core, molding, and grinding instructions in Epicor.
• Liaise between foundry operations and the quality department to address immediate technical concerns.

Weekly Responsibilities

• Manage and document pilot runs: create the pilot schedule, plan gating, perform final part reviews, and oversee destructive testing.
• Attend scrap review meetings and present engineering-based corrective actions.
• Provide technical support to resolve recurring casting or process issues.
• Generate weekly status reports summarizing pilot activity, tooling performance, and scrap metrics.

Periodic / As Needed

• Perform dimensional and visual inspection of nonconforming parts to determine root cause and implement corrective actions.
• Design or revise gating and riser systems for new and legacy parts.
• Audit foundry operations to ensure adherence to standard work, safety practices, and quality procedures.
• Train and coach operators and technicians on process changes, defect recognition, and improved work methods.
• Lead or contribute to safety, quality, and productivity improvement initiatives.
• Maintain technical documentation.
• Communicate issues affecting casting quality to supervisors and stakeholders promptly along with suggested resolutions.
• Perform other duties within the Quality Department as required.

Qualifications

• Associate s degree in engineering, foundry technology, or related field; or 3 5 years of applicable experience in a metal casting environment.
• Strong understanding of foundry processes, gating/riser design, and root cause methodology.
• Proficient in reading technical documents, work instructions, and safety guidelines.
• Ability to prepare reports and present findings to cross-functional teams.
• Working knowledge of Microsoft Office (Excel, Outlook, Word).
• Experience with Epicor or similar ERP systems is a plus.
• Experience with Inspire Cast simulation software is a plus.

Physical Requirements

• Must be able to stand and walk for extended periods.
• Frequently required to use hands for tool or material handling.
• Regular lifting and movement of materials.
• Visual requirements include near/far vision, color distinction, depth perception, and focus adjustment.

Work Environment

• Exposure to loud noise, vibration, airborne particles, and extreme heat is frequent.
• Requires the use of PPE, including but not limited to safety glasses, hearing protection, and heat-resistant gear.