Xaloy
POSITION SUMMARY
The Casting Manager will lead and manage casting and metallurgical initiatives that support operations, manufacturing, and product development. This role focuses on implementing and continuously improving processes that safely and cost-effectively meet or exceed customer expectations for quality, consistency, and on-time performance. As the subject-matter expert in metallurgy and casting, the Casting Manager will apply data-driven decision-making and demonstrate intellectual curiosity to solve complex problems and drive innovation.
This position collaborates cross-functionally with Manufacturing, Engineering, Supply Chain, and Quality teams, and works directly with shop-floor personnel to implement solutions. The role also involves external engagement with customers and vendors, adhering to confidentiality and non-disclosure protocols.
ESSENTIAL RESPONSIBILITIES
Demonstrates company values and shares the organizational commitment to safety, quality, productivity, and a high-performance workforce through positive employee relations.
Safety:
Work Experience Required:
Must be able to perform the following physical demands with or without accommodation:
The Casting Manager will lead and manage casting and metallurgical initiatives that support operations, manufacturing, and product development. This role focuses on implementing and continuously improving processes that safely and cost-effectively meet or exceed customer expectations for quality, consistency, and on-time performance. As the subject-matter expert in metallurgy and casting, the Casting Manager will apply data-driven decision-making and demonstrate intellectual curiosity to solve complex problems and drive innovation.
This position collaborates cross-functionally with Manufacturing, Engineering, Supply Chain, and Quality teams, and works directly with shop-floor personnel to implement solutions. The role also involves external engagement with customers and vendors, adhering to confidentiality and non-disclosure protocols.
ESSENTIAL RESPONSIBILITIES
Demonstrates company values and shares the organizational commitment to safety, quality, productivity, and a high-performance workforce through positive employee relations.
Safety:
- Ensure personal and team compliance with internal policies and external safety, environmental, and health regulations.
- Collaborate with EHS Manager to ensure safety-first process and equipment changes.
- Participate in safety observations and incident investigations.
- Promote a safety-first culture across all operations.
- Oversee bimetallic casting activities including product recipes, testing, NDE, and subcontracted processes.
- Optimize casting process variables such as heat-up time, spin rate/G-forces, mold preheat, melt quality, and inlay bonding.
- Align product and testing priorities with furnace production schedules.
- Maximize casting material utilization while maintaining product integrity.
- Monitor furnace performance and coordinate maintenance and upgrades.
- Ensure complete and accurate documentation of casting records and shop orders.
- Manage process specifications and training requirements.
- Serve as the business expert in materials and additive manufacturing across all locations.
- Stay current with state-of-the-art casting technologies and maintain casting as a core competency.
- Lead product development initiatives, including new inlay/matrix formulations for barrels.
- Apply structured problem-solving tools such as DOE, 5 Whys, FMEA, and Six Sigma to drive improvements.
- Utilize thermal modeling and simulation techniques to optimize casting processes.
- Implement plans to improve product quality and consistency.
- Ensure compliance with quality systems and procedures.
- Investigate customer claims and internal CARs; lead root-cause analysis and corrective actions.
- Develop and report metrics using tools like SPC, SQC, and Lean methodologies.
- Participate in Specific Product Design (SPD) processes to meet customer expectations.
- Review test results for compliance with specifications.
- Lead defect reduction initiatives targeting porosity, lumpiness, and cracking.
- Resolve customer complaints through direct engagement and technical analysis.
- Perform other duties as needed to support company objectives.
- Maintain on-site presence to foster strong relationships and team collaboration.
- Travel (10-20%, including international) to support customer and operational needs.
Work Experience Required:
- Minimum 5 years in a managerial or leadership role within centrifugal casting metallurgy, with hands-on shop-floor experience.
- Proven success managing complex projects in product and process development.
- Bachelor's degree in Materials Science, Mechanical Engineering, Metallurgical Engineering, or related field.
- Strong background in materials or mechanical engineering.
- Deep understanding of casting process variables and defect mechanisms.
- Hands-on experience with centrifugal or high-performance casting.
- Exposure to thermal modeling, melt shop operations, and inlay bonding techniques.
- Strong intellectual curiosity and passion for innovative technology.
- Excellent communication skills for technical and non-technical audiences.
- Effective collaboration across cross-functional teams.
- Strong bias for action and data-based decision-making.
- Exceptional project management and organizational skills.
- Advanced problem-solving and critical thinking abilities.
- Proficiency in Lean / Six Sigma practices.
- Strong Microsoft Office skills (Excel, Word, Power BI, Project, PowerPoint).
Must be able to perform the following physical demands with or without accommodation:
- Ability to sit and utilize a computer for up to 8 hours per day.
- Ability to stand, walk, and move around an office and industrial environment for up to 8 hours a day, including interacting with plant employees in various work centers and identifying products.
- Ability to lift to 40 pounds on an infrequent basis.
- Ability to hear, speak, read, and understand English effectively to communicate with other employees, agencies, and vendors. Additional language skills may be required dependent upon location served.
- Ability to meet the demands of travel, approximately 10-20%, including driving, flying, moving throughout airports, etc.