FerroWorks has locations in Pittsburgh, McKees Rocks, including McConway and Torley and Standard Forged, which have been in continuous operations since 1869, the same year the first US transcontinental railroad was completed. We have been able to meet the needs of our customers with a steady, dependable and economical supply of high-quality railroad industry products. As McConway is the original designers of the first standard automatic coupler, continued innovation and craftsmanship have and has led to a product line that includes every ARR approved coupler as well as custom coupler solutions, which are all proudly cast in the US.
As a Process Engineer, you will support and lead initiatives to optimize foundry manufacturing processes, improve product quality, and increase operational efficiency. This role will provide engineering oversight throughout the production lifecycle, from tooling and molding through casting, finishing, testing, and final inspection. You will collaborate with manufacturing, quality, and engineering teams to identify process improvements, investigate defects, implement corrective actions, and develop data-driven solutions that improve safety, quality, productivity, and cost effectiveness. Some of your key responsibilities will include:
- Analyzing and optimizing existing foundry processes, including pattern and tooling development, molding, melting, casting, finishing, and inspection, to improve production efficiency and product quality
- Leading and supporting continuous improvement initiatives, including Lean manufacturing, value stream mapping, Kaizen events, and workflow optimization
- Collecting, analyzing, and interpreting manufacturing and quality data to identify trends, reduce defects, minimize scrap and rework, and improve process performance
- Investigating manufacturing defects and customer nonconformances, performing root cause analysis, and implementing corrective and preventive actions to prevent recurrence
- Developing, documenting, and maintaining engineering standards, tooling guidelines, process flows, standard operating procedures (SOPs), and work instructions to ensure consistent and repeatable manufacturing processes
- Supporting new product development, process qualification, tooling validation, and engineering changes to ensure products meet applicable customer requirements and industry specifications
- Planning, coordinating, and conducting mechanical and materials testing, including tensile strength, hardness, fatigue testing, and failure analysis, as required
- Supporting non-destructive testing (NDT) activities and developing inspection procedures and acceptance criteria to evaluate internal and external product defects, as applicable
- Coordinating internal and external testing activities to ensure timely completion of product qualification, certification, and compliance requirements
- Evaluating process changes and improvement opportunities using data-driven methods to quantify operational benefits, material savings, and cost reductions
- Collaborating with cross-functional teams, including production, quality, tooling, maintenance, and external testing laboratories, to resolve technical issues and achieve engineering objectives
- Preparing technical reports, presenting engineering findings, and communicating recommendations to management and other stakeholders
- Providing technical guidance and training to production personnel and technicians on manufacturing processes, testing procedures, equipment operation, and standard work practices
Required Qualifications:
- Minimum of 3 years of experience in process engineering, manufacturing engineering, quality engineering, materials testing, or continuous improvement, preferably in a foundry or metal manufacturing environment
- Equivalent Combination of Education and Experience may be considered
Preferred Qualifications:
- Experience with manufacturing process optimization, troubleshooting, and defect reduction
- Strong analytical and problem-solving skills, with the ability to interpret data and develop practical, measurable process improvements
- Knowledge of root cause analysis, corrective and preventive actions (CAPA), and quality improvement methodologies
- Understanding of metallurgy, material properties, mechanical testing, and manufacturing processes
- Strong communication, technical writing, project management, and cross-functional collaboration skills
- Proficiency in Microsoft Office Suite, particularly Excel, for data analysis, documentation, and technical reporting
- Experience with Lean manufacturing, Six Sigma, or other continuous improvement methodologies is preferred
- Experience in steel casting, foundry operations, tooling, molding, or heat treatment is preferred
- Familiarity with non-destructive testing methods, such as ultrasonic testing (UT), phased array ultrasonic testing (PAUT), and magnetic particle inspection (MPI), is a plus
- Experience with fatigue testing, materials qualification, failure analysis, or industry-specific product standards is a plus
- Lean Six Sigma Green Belt, Project Management Professional (PMP), or relevant NDT certifications are preferred
- A commitment to safety and an understanding of the importance of maintaining a safe work environment
Education:
- Bachelor's degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, Manufacturing Engineering, Industrial Engineering, or a related field is required
- Advanced Degree is preferred
Safety Activities
- Be aware of and observe all safety practices, including but not limited to wearing safety glasses, safety boots, hearing protection, and other required personal protective equipment (PPE).
- Know and follow all established safety rules, procedures, and applicable environmental, health, and safety requirements.
- Identify and report unsafe conditions, potential hazards, and near misses in manufacturing, testing, and laboratory environments.
- Ensure engineering trials, process changes, and testing activities are conducted in accordance with established safety procedures.
- Participate in safety committees, training, and continuous improvement initiatives as assigned