Cast House Process Engineer

Hydro Extrusions is a world-leading aluminium extrusion business counting around 100 production sites in 40 countries and employing 20,000 people. Through our unique combination of local expertise, global network, and unmatched R&D capabilities, we can offer everything from standards profiles to advanced development and manufacturing for most industries. Since 1905, Hydro has turned natural resources into valuable products for people and businesses with focus on a safe and good workplace for our 30,000 employees in more than 140 locations.

Job Location: St Augustine, FL.

Hydro employees can enjoy several benefits including:

• Medical, Rx, Dental, Disability, Life Insurance, Flexible Spending Accounts
• Retirement Savings Plans with Company Match/Contributions
• Education Assistance
• Bonus Plan Eligibility
• Parental Leave

Job Summary:

The Process Engineer, Cast House Remelt, will serve as a subject matter expert on all technical aspects of assigned casting processes. This role involves collaborating with supervisors and team members to develop effective solutions for producing high-quality casts safely and efficiently, while minimizing costs and waste.

Required Education/Experience:

• 3 years or more experience in cast house remelt.
• 3 years or more leadership experience.
• Expert proficiency in using metrology tools (e.g., calipers, height gauges).
• Experience with MS Office 365 Suite.
• Effective communication skills, with fluency in English.

Preferred Skills/Qualifications:

• Bachelor’s degree in Electro-Mechanical, Chemical, Electrical, Mechanical or Metallurgical (Materials Science) Engineering.
• Lean Six Sigma Green Belt certification or equivalent preferred.
• Strong problem-solving skills.
• Goal-oriented, with the ability to drive projects to meet production targets.
• Able to read and interpret engineering drawings.
• Comfortable working in a fast-paced environment and flexible with working hours as needed.
• Strong leadership skills, demonstrated through influence rather than direct reporting.
• Bi-lingual preferred.

Job Responsibilities:

• Serve as the subject matter expert (SME) for assigned casting area, conducting research to develop and improve casting processes.
• Optimize casting recipes to balance productivity, quality, and cost.
• Apply A3 thinking to systematically address problems, ensuring viable and permanent solutions, while sharing insights with counterparts.
• Design and plan equipment layouts for new cast house designs and modifications to existing equipment and/or material storage.
• Conduct controlled experiments, DOE, and statistical analysis to monitor process performance and support trends through SPC initiatives.
• Troubleshoot process issues, working closely with operations, maintenance, and quality teams.
• Ensure compliance with environmental and safety regulations in processes and equipment.
• Maximize cast house remelt productivity, streamline product flow, and reduce costs through process optimization.
• Resolve customer issues and assist with quality initiatives on the production floor.
• Lead Corrective and Preventive Actions (CAPA) for quality concerns.
• Provide training to production personnel on quality standards and practices.
• Develop standard work and support the creation and review of safe work practices (JSA).
• Determine appropriate measurement systems for new tool or process design and startup.
• Support short- and long-term plant and companywide goals, Key Performance Indicators (KPI) strategies.
• Adhere to the ISO 9001 principles on quality management.
• Achieve Remelt facility metrics as assigned by the Cast House Manager.
• Ensure effective communication in the group: strategy, goals and actions necessary to achieve.
• Perform quality analysis of off spec cast and decide and execute next steps.
• Attend shift hand offs to effectively communicate ongoing issues and address deficiencies.
• Perform log quality audit and schedule monthly metallurgical testing of various material.
• Other duties as assigned.

Hydro in North America is an Equal Opportunity Employer where all phases of employment are based strictly upon the qualifications of the individual as related to the work requirements of the position. This policy is applied without regard to race, sex, sexual orientation, gender identity, religion, national origin, ancestry, age, disability, veteran status, marital status or any other category protected by law. We strive to provide equal opportunities for all to contribute and succeed with us.

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