Quality and Metallurgy Manager

Company Overview

Castalloy Group is a division of Norican Group. Castalloy is one of the leading producers of high alloy castings and has been producing engineered cast components for over 50 years. The molding processes include airset and shell that enable us to produce castings which have excellent dimensional accuracy and superior surface finish.

Castalloy’s diverse customer base and ability to serve our customers’ needs have earned us a dominant position in the high alloy casting and fabrication industry. We offer contract manufacturing to customer design, custom designs for specific applications and a wide range of standard products.

Continued modernization and automation of manufacturing equipment and environmental controls enable us to maintain our leading position in the marketplace.

Job Title: Quality and Metallurgical Manager

Location: Waukesha, WI

Reports To: Manufacturing Engineering Manager

Part I - Position Purpose

This position is responsible for ensuring the highest standards of product quality and process control in a sand metal casting foundry. This role emphasizes metallurgical knowledge, ISO documentation compliance, scrap reduction, sand testing, and engineering principles to drive continuous improvement.

The position will oversee quality control processes, develop and maintain ISO procedures, analyze casting defects, and collaborate with engineering and production teams to enhance process efficiency and product consistency. By leveraging metallurgical expertise, the role will support root cause analysis, material testing, and supplier quality management to maintain superior casting integrity and customer satisfaction.

Part II – Job Functions

• Lead and oversee ISO certification & compliance, maintaining quality management system (QMS) documentation and conducting internal audits.
• Investigate and resolve customer complaints & returns, implementing corrective actions and preventive measures.
• Plan, coordinate, and execute internal & external audits, ensuring adherence to industry standards and customer requirements.
• Manage the Non-Conformance Reporting (NCR) process, identifying trends and driving corrective actions to reduce defects.
• Oversee metallurgical process control, optimizing melt processes, alloy consistency, and heat treatment to enhance casting quality.
• Review metallurgical aspects of quotes, ensuring alignment with material selection, process capabilities, and cost efficiency.
• Ensure accuracy of Bill of Materials (BOMs), routings, and scrap data in the ERP system.
• Develop and implement training programs for melt department and lab personnel in metallurgical testing and process control.
• Drive quality objectives & product improvements by analyzing data, identifying process enhancements, and implementing best practices.
• Collaborate with team to reduce scrap & casting defects, implementing data-driven solutions to improve foundry operations.
• Minimal travel may be required to provide customer support.
• Other duties as assigned.

Part III – Qualifications and Experience

• Bachelor’s degree in metallurgy is preferred, or commensurate work experience; certification in metallurgical or related is a plus.
• Strong technical and analytical background in foundry quality systems (ISO) and casting defects.
• 3-5 years of experience in a sand foundry environment.
• Strong background in metallurgical chemistry and charge mixes is required.
• Knowledge of running a spectrometer and analyzing samples.
• Must possess strong computer skills with proficiency in Microsoft Office.

Part IV – Personal Characteristics

• Shows ability to comprehend a wide scope of complex technical topics, abstract ideas and specialized information.
• Attention to the relevant details of a project or task with ability to prioritize where focus is needed.
• Exemplary self-management and ability to organize oneself and lead by example for others.
• Ability to effectively build and maintain relationships with fellow team members and all other relevant stakeholders.
• Outstanding written and verbal communication skills to meet the needs of varying communication styles.

Disclaimer

The above statements are intended to describe the general nature and level of work being performed by employees assigned to this job. They are not intended to be construed as an exhaustive list of all responsibilities, duties and skills required for this job.