Sr. Process Engineer Dunkirk

Position Summary

This position serves as a senior technical role responsible for open-die and GFM forging processes at the Dunkirk facility. The role is accountable for developing optimizing and sustaining forging and associated thermal processes to meet customer requirements ensure stable and capable production and drive cost competitiveness.
The individual will work cross-functionally with operations maintenance engineering and commercial teams while directly interfacing with customers to support material qualification process development and technical issue resolution.
This position is expected to grow into the primary technical point of contact for forging processes at the Dunkirk facility.

Core Accountabilities
Establish and own forging process capability for open-die and GFM operations including control of:
o temperature
o strain and reduction
o thermomechanical processing windows
Develop validate and optimize:
o forging routes and reductions
o furnace parameters and heat treatment cycles
o process windows to achieve required mechanical properties and quality
Lead customer qualification and development programs including:
o new material introduction
o process qualification and validation
o alignment of customer requirements with plant capabilities
Drive cost reduction yield improvement and throughput optimization through metallurgical and process improvements
Develop and maintain:
o forging programs and tables for 4K press and GFM
o process standards for both internal products and outside conversion customers
o Disposition and close variances or upgrade to IRR if needed
Serve as the technical lead for outside conversion business including:
o development of forging approaches and routings
o support for quoting and cost structure definition
o identification of new opportunities to grow Dunkirk conversion volume
Define and implement process monitoring and control systems including:
o SPC and capability tracking
o acquisition and analysis of process data
o correlation of process parameters to product performance
Partner with maintenance and engineering to:
o commission and implement new equipment
o define and maintain operating envelopes
o improve process reliability through technical understanding
Lead technical resolution of:
o internal process issues
o customer quality concerns
o deviations and non-conformances
Provide technical leadership and mentorship to engineering and operations personnel

Key Responsibilities
Define control and continuously improve key forging and thermal process parameters- review and update SPC data
Monitor and drive product performance (mechanical properties surface condition dimensional characteristics yield)
Review and interpret customer specifications and ensure technical compliance
Maintain process documentation control systems and associated databases
Support management review with data-driven analysis and recommendations
Interface with customers sales and leadership to resolve any differential between customer requirements and SMC capabilities.
Technical supervision of Dunkirk Processes and employees

Qualifications
Education & Experience
Bachelors or Masters degree in Metallurgical Engineering or Materials Science
Minimum 812 years of experience in forging and thermomechanical processing of high-performance alloys