Foundry Manager

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:

Manage day-to-day foundry production to meet schedule, safety, quality, and throughput targets. Lead supervisors/leads and coordinate staffing, training, and performance management. Drive process discipline across melting, molding, pouring, shakeout, and finishing operations. Partner with Engineering and Quality on defect reduction, process capability, and corrective actions. Maintain equipment readiness with Maintenance; prioritize downtime issues and preventative maintenance. Ensure compliance with safety procedures, PPE, and hazard reporting; lead safety meetings and investigations. Monitor production KPIs and implement continuous improvement initiatives. Control labor and material costs; manage scrap, rework, and yield improvement programs. Ensure accurate production reporting, traceability, and standard work documentation. 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 Qualification s

Education, Experience, or Formal Training:

5+ years manufacturing leadership experience; foundry/metal casting experience preferred. Strong knowledge of safety practices, production scheduling, and continuous improvement methods. 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:

Frequent standing/walking; ability to wear PPE/respiratory protection as required. Ability to lift up to 50 lbs occasionally and work around industrial equipment and elevated temperatures.

KPIs:

Safety incident rate (TRIR) and near-miss reporting Production attainment vs. schedule Scrap and rework rate Yield / melt-to-ship efficiency Downtime hours and top causes Overtime hours as % of labor First Pass Yield (FPY) on foundry operations On-time handoff to downstream machining/finishing Training compliance for operators 5S/audit score for foundry areas

SMART Goals:

Reduce recordable incidents by 25% within 12 months by increasing near-miss reporting and closing actions within 14 days. Achieve 95% production attainment weekly within 120 days through daily tier meetings and constraint management. Reduce scrap/rework by 15% within 9 months by eliminating top-3 defect drivers via RCA and process controls. Improve yield by 5% within 6 months by optimizing charge materials and controlling key process parameters. Cut unplanned downtime by 10% within 2 quarters by implementing PM schedules and downtime Pareto reviews. Reduce overtime by 8% within 6 months through staffing plans and improved schedule adherence. Increase FPY by 8 points within 2 quarters through standardized work and operator training refreshers. Deliver 95% on-time handoff to machining for 2 consecutive quarters via WIP controls and communication routines. Achieve 100% required training completion within 60 days for all foundry operators using a training matrix. Raise foundry 5S/audit score to 85% within 90 days by weekly audits and owner assignments.