Position Summary: Operations Leads foundry operations to safely produce cast products that meet quality, delivery, and cost targets through effective people leadership and process control. Essential Functions: u2022 Manage day-to-day foundry production to meet schedule, safety, quality, and throughput targets. u2022 Lead supervisors/leads and coordinate staffing, training, and performance management. u2022 Drive process discipline across melting, molding, pouring, shakeout, and finishing operations. u2022 Partner with Engineering and Quality on defect reduction, process capability, and corrective actions. u2022 Maintain equipment readiness with Maintenance; prioritize downtime issues and preventative maintenance. u2022 Ensure compliance with safety procedures, PPE, and hazard reporting; lead safety meetings and investigations. u2022 Monitor production KPIs and implement continuous improvement initiatives. u2022 Control labor and material costs; manage scrap, rework, and yield improvement programs. u2022 Ensure accurate production reporting, traceability, and standard work documentation. u2022 Coordinate with Planning/Shipping to align output to customer delivery commitments. Additional Skills by Level Level I: Stabilize safety and production routines; improve visibility of daily KPIs and shift handoffs. Level II: Improve capability and yield through structured CI, training, and equipment reliability programs. Level III: Lead major process upgrades, capacity expansion, or multi-shift transformation with enterprise impact. Job Requirements and Qualifications Education, Experience, or Formal Training: u2022 5+ years manufacturing leadership experience; foundry/metal casting experience preferred. u2022 Strong knowledge of safety practices, production scheduling, and continuous improvement methods. u2022 Ability to lead teams in a high-heat, industrial environment with strong communication and discipline. Working Environment: Hot, noisy foundry environment with dust/fumes and heavy equipment; PPE required frequent walking and standing; extended hours may be needed. Physical Demands: u2022 Frequent standing/walking; ability to wear PPE/respiratory protection as required. u2022 Ability to lift up to 50 lbs occasionally and work around industrial equipment and elevated temperatures. KPIs: u2022 Safety incident rate (TRIR) and near-miss reporting u2022 Production attainment vs. schedule u2022 Scrap and rework rate u2022 Yield / melt-to-ship efficiency u2022 Downtime hours and top causes u2022 Overtime hours as % of labor u2022 First Pass Yield (FPY) on foundry operations u2022 On-time handoff to downstream machining/finishing u2022 Training compliance for operators u2022 5S/audit score for foundry areas SMART Goals: u2022 Reduce recordable incidents by 25% within 12 months by increasing near-miss reporting and closing actions within 14 days. u2022 Achieve u226595% production attainment weekly within 120 days through daily tier meetings and constraint management. u2022 Reduce scrap/rework by 15% within 9 months by eliminating top-3 defect drivers via RCA and process controls. u2022 Improve yield by 5% within 6 months by optimizing charge materials and controlling key process parameters. u2022 Cut unplanned downtime by 10% within 2 quarters by implementing PM schedules and downtime Pareto reviews. u2022 Reduce overtime by 8% within 6 months through staffing plans and improved schedule adherence. u2022 Increase FPY by 8 points within 2 quarters through standardized work and operator training refreshers. u2022 Deliver 95% on-time handoff to machining for 2 consecutive quarters via WIP controls and communication routines. u2022 Achieve 100% required training completion within 60 days for all foundry operators using a training matrix. u2022 Raise foundry 5S/audit score to u226585% within 90 days by weekly audits and owner assignments.
Job Title
Foundry Manager