Foundry Process Improvement Engineer

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Join Our Team at voestalpine Railway Systems Nortrak!​

Embark on a rewarding career journey with voestalpine Railway Systems Nortrak, North America's premier designer and manufacturer of special trackwork. With a legacy spanning 160 years, we lead the industry in shaping the future of rail solutions. As part of the voestalpine Railway Systems global network, we are committed to delivering quality products and services, including rails, turnouts, fastening systems, signaling technologies, and monitoring solutions. Operating with a presence across Canada, the US, and Mexico, we prioritize the well-being of our people, global mobility, and sustainability and innovation.​

Our people are the foundation of our success. Skilled, motivated, and results-driven individuals shape our culture demonstrating our core values of Respect, Responsibility, Curiosity, Courage, Passion, and Diversity each day. This commitment is more than shared values; it extends to shared responsibilities for safety and quality, showing genuine care for one another's growth and development, a commitment to our customers, and fostering strong relationships within the Nortrak Team and with our customers.​

We are currently looking for a Plant Controller / Cost Controller to join our team in Decatur, IL.

PURPOSE OF POSITION  

Reporting directly to the Plant Manager, the Foundry Process Improvement Engineer is responsible to utilize lean manufacturing, process control and foundry experience to insure the continual improvement of the ductile and manganese foundry.

TASKS & RESPONSIBILITIES  

Safety:  

• Comply with and enforces all Nortrak safety policies and regulations.  
• Participate in development and review of JSAs, set up instructions, hazard analysis of new foundry equipment and processes, and resolution of any assigned safety committee issues.  
• Review and approve foundry work instructions and PPE requirements to ensure safe operation.  
• Ensure that outside vendors adhere to plant safety regulations and that MSDS for new and existing materials are reviewed, approved and filed.

QUALITY:

• Perform 5S and Kaizen events and engage employees in the continuous improvement process. 
• Be responsible for helping develop, implement, maintain, and improve standard processes, quality systems, capacity planning and scheduling systems. 
• Evaluate existing foundry processes and develop proposals for methods, equipment, layouts and materials for cost reduction, quality and process enhancement, and safety.
• Plan and optimize material flow through effective utilization of foundry equipment capacity, supplier capabilities, and material lead time as well as through leveraging outside capacity as needed
• Prepare written graphical work instructions for production staff.
• Evaluate multiple potential solutions to derive the optimum solution using different problem solving techniques such as A3 or the 8D process
• Review foundry process control techniques to ensure measuring and recording techniques employed are accurate and that monitoring protocols are adequate to effectively control foundry processes and facilitate troubleshooting.  
• Manage process control data within QCS and effect process changes to reduce scrap rates and improve product quality. 
• Maintain an extensive knowledge of applicable quality standards and procedures. Establish/adhere, audit and enforce vendor quality procedures and specifications.
• Rig new castings as well as improve rigging on current products.  Provide input to the methods drawings in order to maintain legacy of successful rigging.
• Design and carry out test trials targeting product, process, and quality improvement. 

ON-TIME DELIVERY: 

• Develop key manufacturing strategies and concepts that enhance employee safety, ensure quality in manufacturing processes, increase part flow/production and reduce production time and cost. 
• Collaborate with Production Planning to designate machine utilization. 
• Assist the engineering department in transitioning new designs into production.
• Develop and implement plans to improve foundry productivity. 
• Ensure timely development and verification of moulding and rigging. 
• Manage relationships with internal/external customers and vendors; ensure appropriate communications prevent delays due to sourcing or delivery issues.

Cost: 

• Assist in the cost estimating and quote preparation of cast components 
• Lead foundry process improvements.  
• Manage capital projects including justification, specifications, negotiation of price and terms, and oversee successful implantation or installation.  
• Assist in maintenance, repair and commissioning of equipment. Work with production  personnel to identify enhanced facility designs/layouts, create and implement enhanced manufacturing processes, and recommend capital improvements projects which support annual company objectives
• Ensure timely development and verification of moulding and rigging. 
• Manage relationships with internal/external customers and vendors; ensure appropriate communications prevent delays due to sourcing or delivery issues.

People:

• Must be able to work with vendors, plant, and maintenance personnel to design, modify, and install equipment and perform facility modification.  
• Must be able to work with production and maintenance personnel, vendors and other Nortrak plant personnel in a team-oriented environment. 
• Works with Maintenance Department to identify/resolve any equipment issues/concerns   
• Coach and mentor foundry technical and operating personnel.

ENVIRONMENTAL:  

• Adhere to Nortrak's Environmental Procedures, Practices and Policies.

Other Duties as Assigned

Education:

• Bachelor’s Degree in Manufacturing or Industrial Engineering or other technical discipline.
• Minimum of 5+ years of manufacturing related experience, exposure to foundry is an asset.

Experience: 

• Experience with low volume/high component mix environment. Ability to troubleshoot foundry processes at the shop level.
• Understanding of lean methodologies.
• Strong knowledge of cost analysis, work simplifications and value stream analysis. 
• Proven experience with foundry equipment capacity planning Advanced Excel, Word, and Power Point skills
• Excellent written and verbal communication skills.

PHYSICAL DEMANDS WHEN AT MANUFACTURING FACILITIES:

• Prolonged periods of sitting at a desk and working on a computer
• Occasional standing, walking, stooping, kneeling, crouching, or climbing.
• Must be able to lift or handle up to 25 pounds at times.
• Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception and ability to adjust focus.
• Occasional travel may be required which includes walking, standing, sitting, and driving from short to long periods of time.

Thanks and Best Regards,

Carolyn Wong

Talent Acquisition Specialist

voestalpine Railway Systems Nortrak

5500 Parkwood Way

• Richmond, BC, V6V2M4
• Direct: (604) 231-3559
• Mobile: (307) 214-0398
• Fax: (604) 273-8927

Email: carolyn.wong@voestalpine.com