Process Engineer, Casting

Job Summary:

The Casting Process Engineer plays a critical role in supporting daily casting operations and ensuring stable, high‑quality casting processes. This role requires floor presence to provide direct technical support, drive process discipline, and actively engage with operators and production leadership. The remaining time is dedicated to engineering analysis, documentation, and project execution.

Responsibilities:

Shop Floor Responsibilities

• Provide daily hands‑on technical support across melting, , holding, treatment and casting areas within the Ravenswood Casting department.
• Act as the primary process and quality presence on the floor, supporting operators, crews, and production and maintenance supervisors with real‑time problem solving.
• Identify and resolve casting defects by performing on‑floor root cause analysis and verifying process parameters.
• Ensure casting equipment, core operations, casting practice parameters are operating within standard requirements specific to Ravenswood’s product mix.
• Conduct Gemba walks and process audits to reinforce safety, quality, and process discipline.
• Monitor scrap, rework, downtime, and bottlenecks as they occur, responding quickly to reduce impacts on production schedules.
• Support sample runs, trials, and tooling introductions directly at the line, collaborating closely with Tooling, Maintenance, and Quality.
• Coach operators on standard work, casting quality checks, safety protocols, and best practices aligned with Ravenswood training expectations.

Office responsibilities

• Update work instructions, PFMEAs, control plans, and engineering documentation to reflect actual Ravenswood floor practices.
• Analyze scrap, melt chemistry trends, cycle times, and productivity metrics to identify improvement opportunities.
• Lead and document corrective actions, engineering changes, and process validations.
• Utilize simulation software or analytical tools to support gating/risering optimization or process improvements.
• Prepare technical reports, presentations, and daily/weekly updates for production and plant leadership.
• Drive continuous improvement aligned with Ravenswood KPIs (scrap reduction, throughput, cost savings, and process capability).

Qualifications:

• Bachelor’s degree in engineering field is strongly preferred, but not required.
• 1–3 years of related experience in casting or foundry operations, strongly preferred.
• Strong understanding of casting defects, melt practices, and solidification fundamentals.
• Experience with process troubleshooting, SPC, and quality systems.
• Working knowledge of engineering tools such as PFMEA, Control Plans, DOE, and 5‑Why.
• Ability to communicate effectively with floor operators, supervisors, and management.
• Comfortable working extensively in a casting/production environment (heat, noise, dust).
  • PPE required: safety glasses, steel‑toe boots, hearing protection, and casting‑specific protective gear
• Hands-on, proactive, and highly engaged work style
• Familiarity with lean manufacturing and continuous improvement methodology
• Experience with simulation software (MAGMA, ProCAST) is a plus
• Strong problem-solving and data-analysis abilities
• Ability to train, mentor, and influence the production team

Dimensions:

The Casting Process Engineer is responsible for overseeing and optimizing metallurgical and production processes across the Casting department. The role focuses on maximizing material recovery, eliminating process waste, improving productivity, and reducing conversion costs through multidisciplinary process solutions that integrate electrical, mechanical, metallurgical, and process‑flow knowledge. This position leads focused improvement projects, strengthens process control discipline, and ensures compliance with all departmental quality system requirements. The Casting Process Engineer also supports customer satisfaction with quality by maintaining consistent product performance and driving continuous improvement in process capability.

About Constellium
With ~1,100 employees, Constellium’s plant in Ravenswood, West Virginia, is one of the world’s largest rolled products facilities, offering customers the most powerful plate stretchers in the world, as well as one of the largest cold rolling mills. Built in 1957, the plant houses 62 acres (about 250,900 m²) of production facilities, and is one of the top 50 businesses in West Virginia. 

We produce plate, sheet, and coil products for aerospace, defense, transportation, marine, and industrial uses. As the global leader in aluminum aerospace technology, we specialize in high performance plates, sheets and extrusions that bring cost and performance benefits to space programs and military and commercial aircraft. Our advanced aluminum products manufactured in the US, France and Switzerland can be found in platforms manufactured by Airbus, Applied Materials, Blue Origin, Boeing, Bombardier, Dassault, Embraer, General Dynamics, LAM, Lockheed Martin, SpaceX and others. The Ravenswood facility is nestled in the foothills of the Appalachian Mountains, along the Ohio River. It is the largest employer in Jackson County, and one of the top 50 businesses in West Virginia.

A culture of family, community, and hard work runs deep in Jackson County. Located in the western region of West Virginia, it is one of the most productive regions in the state, with Ripley as its county seat and Ravenswood serving as its largest municipality. Ripley sits between the Parkersburg and Charleston metropolitan areas.

The region offers plenty of activities, both open-air and indoors, for a wide range of interests. These include parks, lakes, forests, Civil War trails, golf courses, historical landmarks (covered bridges, a heritage house, a castle), museums and galleries, conference centers, the Clay Center for the Arts and Sciences, the Charleston Light Opera Guild, and much more.

Constellium is an Equal Opportunity Employer: Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.