Process Engineer at CastAlum

, Wales, United Kingdom -

Full Time

Start Date

Immediate

Expiry Date

16 Apr, 26

Salary

0.0

Posted On

16 Jan, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

High-Pressure Die Casting, Technical Decision Making, Process Optimisation, Root Cause Analysis, Shot Monitoring Software, SPC Analysis, Gating Systems, Venting Systems, Vacuum Systems, Die Cooling, Metal Flow Dynamics, Problem Solving, Continuous Improvement, Six Sigma, Lean, Robotics

Industry

Manufacturing

Description

Company Description CastAlum is an internationally acclaimed aluminium die casting and machining centre located in Welshpool, UK. The site was a Greenfield development in the winter of 2000-2001, serving one customer only. 20 years on, the company supplies parts to the UK, Europe, Canada, and Mexico. We have grown from die casting aluminium parts only to supplying a range of products (using high pressure die casting, squeeze die casting, and machining). We can supply aluminium components as cast, cast & machined, or assembled & tested according to the needs of our customers. Job Description The Process Engineer is the on-shift technical authority responsible for leading all process-related decision making across the high-pressure die casting (HPDC) department. The role ensures casting processes are stable, capable, and optimised to deliver quality, safety, and productivity targets. Working closely with Process Technicians & the Production, Maintenance, Toolroom and Quality departments. The Process Engineer provides advanced technical support, root cause analysis, and methodical process optimisation using recognised die casting methodologies. Key Responsibilities Leadership & Decision Making Act as the highest level of on-shift technical decision maker for all HPDC processes. Provide direction to Process Technicians on process adjustments, die changes, and fault diagnosis. Lead start-ups, restarts, die trials, parameter validation, and approval of first-off samples. Set up and be involved in all automation processes for Die cast Cells. (6 axis robots, Conveyor systems) Ensure that all process changes are controlled, logged, and aligned with engineering standards. Make safe, effective decisions under time pressure to maintain production and minimise downtime. Work closely with the Process Supervisor and Manager on company objectives. Qualifications Skills, Experience & Qualifications Essential Strong background in high-pressure die casting (HPDC), ideally in automotive-grade environments. Proven experience analysing shot profiles, thermal behaviour, and casting defects. Ability to lead technical decision-making and guide teams under pressure. Strong understanding of gating, venting, vacuum systems, die cooling, and metal flow dynamics. Proven problem-solving ability using structured methods and data-driven decision making. Competent with shot monitoring software, SPC analysis, and process documentation. Desirable Degree or HNC/HND in Mechanical, Manufacturing, Metallurgy, or related engineering field. Experience with aluminium alloys. Familiarity with DOE methods, Six Sigma, and statistical tools. Strong understanding of hydraulic systems, accumulators, and servo-controlled shot systems. Experience in continuous improvement programs (Kaizen, Lean). KUKA and ABB 6 axis robot knowledge / experience. Additional Information Life insurance On-site parking Sick pay

Responsibilities

The Process Engineer leads all process-related decision making in the high-pressure die casting department, ensuring processes are stable and optimized. They provide technical support and conduct root cause analysis while working closely with various departments.