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.
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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
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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
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Qualifications
Education & Experience
* Bachelor's or Master's degree in Metallurgical Engineering or Materials Science
* Minimum 8-12 years of experience in forging and thermomechanical processing of high-performance alloys

With more than 120 operations and approximately 20,000 employees worldwide, Precision Castparts Corp. is the market leader in manufacturing large, complex structural investment castings, airfoil castings, forged components, aerostructures and highly engineered, critical fasteners for aerospace applications. In addition, we are the leading producer of airfoil castings for the industrial gas turbine market. We also manufacture extruded seamless pipe, fittings, and forgings for power generation and oil & gas applications; commercial and military airframe aerostructures; and metal alloys and other materials for the casting and forging industries. With such critical applications, we insist on quality and dependability - not just in the materials and products we make, but in the people we recruit.

PCC is relentless in its dedication to being a high-quality, low-cost and on-time producer; delivering the highest value to its customers while continually pursuing strategic, profitable growth.

In 2016, Berkshire Hathaway, led by Chairman and CEO Warren E. Buffett, acquired Precision Castparts Corp.