Senior Process Metallurgist

Charter Manufacturing is a fourth-generation family-owned business where our will to grow drives us to do it better. Join the team and become part of our family! Charter Casting is hiring a Senior Process Metallurgist! Alternative Job Titles: Senior Manufacturing Metallurgist, Lead Process Metallurgist, Senior Metallurgical Engineer Job Summary: As a Senior Process Metallurgist, you will provide technical leadership with a strong focus on metallurgical and process engineering across the Melt, Laboratory, and Continuous Casting operations. You will apply materials science, metallurgy, and manufacturing-process expertise to improve safety, quality, productivity, and cost. Partnering closely with Operations and cross-functional teams, you will troubleshoot complex technical issues, strengthen process controls and standards, optimize melting and casting practices, support new-product development, and implement sustainable process improvements. This role serves as a primary technical resource for manufacturing process performance and product quality. Position specifics: • Location: Woodstock, IL • Schedule: Onsite • Travel: Up to 10% travel • Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time. Key responsibilities: Metallurgical & Process Engineering Leadership • Provide technical leadership for Melt, Laboratory, and Continuous Casting processes by developing and improving metallurgical standards, manufacturing processes, and operating practices. • Develop and improve melt recipes, process instructions, and standards for molten metal processing, product analysis, and product release. • Evaluate and adjust manufacturing processes based on raw material quality, chemical composition, cost, product requirements, and process performance. • Improve melting and continuous casting processes, including die and cooler design, crucible design, refractory practices, molten metal handling, and critical process variables. • Strengthen metallurgical quality and process consistency for gray and ductile cast iron products. Process Optimization & Technical Problem Solving • Partner with Operations to troubleshoot manufacturing, process, and quality issues; lead root cause analysis and implement sustainable corrective actions. • Analyze manufacturing, laboratory, quality, and process data to identify trends, reduce manufacturing losses, improve yield, and strengthen process capability. • Lead process improvement projects through data analysis, process validation, production trials, and implementation of sustainable improvements. • Investigate and resolve quality problems identified during manufacturing or through customer returns, including defect and failure analysis. • Apply process engineering and continuous-improvement tools, including Design of Experiments, statistical analysis, process mapping, DMAIC, root cause analysis, and Lean principles. Technical Systems, Projects & Product Support • Maintain MES process master data and provide technical support for manufacturing system enhancements, troubleshooting, and process optimization. • Support capital projects involving manufacturing equipment, tooling, furnaces, holders, refractory systems, and process improvements. • Serve as the primary technical resource for new-product quoting by evaluating manufacturing feasibility, process capability, and technical risk. • Partner with Procurement in qualifying new suppliers and ensuring incoming raw materials meet required technical and quality standards. • Support the development and qualification of new or improved products, materials, manufacturing technologies, and process capabilities. Cross-Functional Collaboration & Technical Expertise • Collaborate with Operations, Quality, Maintenance, Engineering, Supply Chain, Sales, and Technical Services to solve technical problems and support strategic initiatives. • Support Commercial and Sales teams as a technical resource for customer application questions, quality concerns, processing recommendations, and product performance. • Develop and maintain manufacturing standards, work instructions, operating procedures, and technical documentation. • Share technical knowledge and mentor employees on metallurgy, materials science, process controls, manufacturing processes, and continuous-improvement practices. • Support Environmental, Quality, and Safety Management Systems and ensure compliance with company policies and regulatory requirements. What you’ll need: • Bachelor’s Degree in Metallurgical Engineering, Materials Science, or a related engineering discipline. • Five or more years of experience in a metallurgical, materials, manufacturing, or process engineering environment. • Strong understanding of metallurgy, materials science, cast iron manufacturing, process control, and data analysis. • Demonstrated success solving complex technical problems and improving manufacturing processes. • Strong analytical, troubleshooting, root cause analysis, and problem-solving skills. • Ability to lead cross-functional projects and influence others without direct authority. • Strong verbal, written, and presentation skills. • Experience with SolidWorks 2D/3D CAD software, or willingness to learn, to support tooling, equipment, and process improvements. • Proficiency with Microsoft Office and manufacturing data analysis tools. • Ability to manage multiple priorities in a fast-paced manufacturing environment. • Demonstrated commitment to safety, quality, and continuous improvement. • Willingness to travel up to 10%. Nice to haves: • Master’s Degree in Metallurgical Engineering, Materials Science, Engineering, Operations Management, or a related field. • Experience with induction melting and production of gray and ductile cast iron. • Experience with continuous casting operations and cast iron manufacturing. • Experience with metallurgical laboratory equipment, including optical emission spectrometers and LECO analyzers. • Experience in defect analysis, failure analysis, and customer-facing technical support. • Experience developing new or improved products. • Experience with ISO or Quality Management Systems. • Experience with MES and ERP systems supporting manufacturing processes; Oracle ERP experience is a plus. • Lean Manufacturing and/or Six Sigma Green Belt certification, or equivalent continuous-improvement experience. • Experience leading or supporting capital improvement projects involving manufacturing equipment, tooling, furnaces, holders, or process improvements. • Proficiency with statistical analysis, process mapping, and data visualization tools. Take the next step in your career, apply today! About Charter Casting Charter Casting is a premier U.S. partner and casting supplier for precision-engineered iron solutions. We deliver large, complex iron castings and DuraBar®, the industry’s leading continuous cast iron bar, with the consistency and performance customers depend on. #LI-PF1 #CharterManufacturing #CharterCareers #OneFamilyOneTeam #CharterCasting The annual hiring range for this position is: $100,000-$125,000. The actual base pay offered to the successful candidate will depend on various factors, including but not limited to job-related skills, experience, and qualifications. Compensation decisions are tailored to the unique circumstances of each position and candidate. We offer comprehensive health, dental, and vision benefits, along with a 401(k) plan that includes employer matching and profit sharing. Additionally, we offer company-paid life insurance, disability coverage, and paid time off (PTO).