Casthouse Process Engineering Manager

Casthouse (Remelt) Process Engineer serves as subject matter expert working with the "Flow Path" team in the production of cast aluminum ingot, procurement and hands-on problem resolution. Position emphasis is on the safety, productivity, quality, and financial improvements surrounding the casting process and Flow Path system scheduling. This position has a key role "Flow Path" structure for the mill to support Kaiser Select continuous systems improvements initiatives.

Responsibilities

• Key lead in assisting with the Flow Path (Production Control/Casting/Extrusion) system scheduling process.

• Monitor and track Kanban system in Scrap receipts/Cast schedule through system flow process to minimize production downtime and report on Flow Process effectiveness.

oProvide technical support in trouble-shooting, checking, testing, and evaluating Cast status for production.

oSupport Casting systems and Production planning/scheduling improvements such as alloy blending.

• Participate in the ongoing FMEAs, Control Plans, Flow Analyses and other documentation to support Flow Path system needs.

• Assist in the development training programs for hourly staff to support ongoing Flow Path employee development system improvements.

• Work directly with day to day process troubleshooting and problem solving

• Understands and support plant safety, SI reporting, ISO 9000, PPC, CPC and 14001 requirements. Ensures that safety and environmental standards are met in working area.

• Software Systems: Data Integration and Implementation

oImprove overall responsiveness and efficiency, resulting in a lower cost of quality.

oIdentify and systemically reduce variation, resulting in less waste, scrap and rework.

oKnowledge of SQL servers, databases, and networks.

oKnowledge of recipe management systems including KRS and Jobscope.

• Six Sigma Green Belt Certified Preferred

oImprove the quality of process outputs by identifying and eliminate defects and minimizing variability in manufacturing and business processes.

oUse of DMAIC in problem solving and ability to evaluate processing methods.

• Ability to perform research, design, and development of manufacturing processes including production flow, production equipment, and cost-justify various tools for recommended manufacturing methods.

oApply Lean Manufacturing techniques to perform product/process analysis for cost reduction, quality improvement, and improved efficiency.

oProvide improvements in metal manufacturing processes such as time studies, yield, and scrap analysis.

oSupport continuous improvement in scrap and metal recovery through analytical methods involving Excel, Maximo, and database systems.

oResponsible for special projects and entering process improvement changes, monitoring and supporting continuous improvement of manufacturing systems, support employee training, and hands on coaching in order to assure compliance to defined process and product criteria.

• Have experience in spectro analysis.

Relationships

• Report to Plant Manager

• Work closely with Extrusion Manager, Maintenance Manager, Production Control Manager in supporting role to Flow Path system effectiveness

• Interacts daily with production staff, functional department leaders, and support groups

Background and Preferred Skills

• A Bachelor's Degree in Material Science, Mechanical Engineering, OR equivalent relevant experience is required

• 4+ years of Casting or Remelt experience is required

• Solid verbal and written communication skills. Bilingual Spanish a plus.

• Excellent interpersonal skills

Measures of Performance

• ISO-14001 system compliance

• No OSHA or CAL OSHA violations

• Compliance with environmental rules and regulations

• Significant Injury and Fatality (SIF) Road Map audit compliance

• TCIR / LCIR exceeds yearly goals (2.0 / 0.0 currently)

• Successful completion of quality audits

• Corporate Safety Leading/Lagging Indicators

• SIF Road Map Risk Reduction

• Strategic Safety Plan (SMART) completion