Senior Process Control Technician - Die Cast Parameters & Defect Reduction Up to $41.00/hr ($85,280/yr)

• Cedarburg, WI Area
• 3rd Shift
• Direct-Hire /

Full-Time Compensation & Earnings:

Starting pay up to $41.00/hr ($85,280/yr baseline depending on experience), pay-for-performance bonus opportunities, 401(k) with company match, and full health/dental/vision benefits.

Schedule & Work-Life Balance:

Dedicated 3rd shift schedule with opportunities to earn additional hours of bonus PTO per year for strong attendance.

Work Environment & Company Profile:

Join one of the largest independent die casting manufacturers in North America featuring exceptional stability, 40% employee tenure over 10+ years, and premier tier-one OEM partnerships.

Core Functional Scope:

Monitor and optimize high-pressure aluminum die casting process parameters, conduct root-cause analysis on casting defects, and maximize first-pass yields.

Strict Requirements & Authorization:

Strict job stability required (minimum 2+ years per employer); 2+ years of process control or technical troubleshooting in manufacturing; local commute within 45 minutes of Cedarburg, WI; U.S. work authorization. A premier, North American market leader in high-precision die casting is seeking a driven Process Control Technician to oversee and optimize process integrity on their 3rd shift production floor. Responsible for monitoring critical variables on automated, high-pressure aluminum casting cells, this seat plays a direct role in driving down scrap, troubleshooting complex part defects, and ensuring strict compliance with tier-one OEM quality standards. Joining an ISO-certified facility where 40% of the team boasts over a decade of tenure, this direct-hire position offers outstanding hourly earnings, long-term stability, strong 401(k) matching, and structured career advancement opportunities. What You Will Be Doing (Daily Responsibilities)

Monitor Process Parameters:

Continuously track and analyze critical variables including melt temperatures, shot profiles, injection speeds, intensification pressures, cycle times, and die lubrication.

Analyze & Resolve Casting Defects:

Perform root-cause analysis on defect issues such as porosity, cold shuts, soldering, blisters, flash, misruns, and thermal shrinkage.

Optimize Machine Parameters:

Set up, fine-tune, and validate die casting process parameters for new product launches, die tryouts, and existing production runs.

Maintain Process Standardization:

Establish, document, and maintain accurate process setup sheets and operating instructions for setup techs and machine operators.

Execute Production Trials:

Collaborate with quality and engineering teams to validate process changes, improve first-pass yield, and minimize scrap rates.

Support Quality & Inspection:

Utilize real-time process monitoring systems and review X-ray inspection data to ensure parts meet customer specifications.

Train Floor Personnel:

Coach and train machine operators and setup technicians on standardized process parameters and operational best practices. What We Are Looking For (Requirements & Qualifications)

Job Stability Required:

Demonstrated career stability with a strict requirement of at least 2+ years of tenure at each previous employer.

Manufacturing Process Experience:

2+ years of hands-on experience in process control within a manufacturing environment (aluminum die casting, plastic injection molding, or metalworking preferred).

Technical & Analytical Aptitude:

Strong problem-solving skills with the ability to interpret process monitoring data, thermal profiles, and quality reports.

Commutable Radius:

Must reside within a 45-minute maximum commute of the Cedarburg / Greater Milwaukee, WI area.

Education & Authorization:

High School Diploma or GED required; technical diploma or vocational degree in manufacturing technology or metallurgy preferred. Must be fully authorized to work in the United States without sponsorship. Preferred Technical Assets (Bonus Skills)

Die Cast & Vacuum Systems:

Specialized background in high-pressure aluminum die casting, vacuum-assisted die casting, or molten metal thermal management.

Automation & Quality Standards:

Familiarity with robotic automation, real-time shot monitoring software, X-ray inspection analysis, and

IATF 16949

quality guidelines.

Lean & Continuous Improvement:

Practical experience with Six Sigma methodology, 5S, Pareto analysis, or formal root-cause analysis frameworks.