Corporate Casting Director/SME

Good Day!
NES Fircroft is excited to share that our office has partnered with a dynamic renewable energy/Chemical organization as they have an immediate need for a Corporate Cast Director. This is a permanent job opportunity that would entail traveling to different plants to lead and oversee the technical aspects of aluminum casting operations across our manufacturing mills. This role is focused on providing expert leadership and technical guidance to ensure the optimization of casting processes, particularly billet casting, while driving innovation and quality across all casting operations. The Corporate Casting Technical Director will work closely with senior management, engineering teams, production, and quality control departments to ensure the highest standards of quality, efficiency, and safety are maintained in all casting-related processes across the organization.
If this sounds like a great opportunity for yourself or someone you know, please reach out to Tom Rebellato at tom.rebellato@nesfircroft.com. Additional job details can be found below.

Job Details
Location: Goose Creek, SC—Remote candidates can be considered but would increase the travel frequency. Expected travel between 50%-75% of the time.   
Hours: M-F 40 hours per week—some OT may be required.
Pay Range: $190,000-$210,000 per year depending on experience + up to 25% yearly bonus, stock incentives and full benefits package.
Duration: Direct Hire 
 
Responsibilities

• Strategic Oversight of Casting Operations:
  • Provide corporate-level leadership and oversight of all aluminum casting operations, including billet casting, in multiple manufacturing facilities.
  • Develop and implement corporate-wide casting strategies, process improvements, and technology adoption to drive quality, efficiency, and consistency across all plants.
  • Lead the development and standardization of casting processes, ensuring that best practices are followed and are in line with industry standards.
• Billet Casting Expertise & Process Optimization:
  • Spearhead the optimization of billet casting operations across all plants, ensuring that the process delivers high-quality billets with minimal defects (e.g., porosity, segregation, surface quality).
  • Provide technical expertise in billet casting technologies, such as direct chill (DC) casting and continuous casting, to enhance yield, reduce waste, and improve overall product quality.
  • Work closely with plant engineering teams to troubleshoot and resolve technical challenges related to billet production.
• Quality Control & Continuous Improvement:
  • Ensure that all aluminum castings, particularly billets, meet or exceed customer specifications and industry standards by setting up rigorous quality control processes.
  • Drive continuous improvement initiatives across casting processes, focusing on reducing defects, improving efficiency, and implementing cost-saving measures.
  • Work with the Quality Control team to establish and maintain consistent metrics for billet quality, and ensure data-driven decisions are made to drive improvements.
• Technical Leadership & Team Development:
  • Provide leadership and mentoring to regional and plant-level casting teams, including engineers, technicians, and operators, to build technical expertise in casting processes.
  • Organize training programs and seminars to improve technical knowledge of casting operations across all levels of staff.
  • Foster a culture of innovation and continuous learning in casting processes, ensuring that new technologies and methods are explored and implemented where beneficial.
• Safety & Compliance Oversight:
  • Lead the implementation and enforcement of strict safety protocols in casting operations, particularly with respect to the handling of molten aluminum and the safety of billet casting processes.
  • Ensure that all casting processes meet regulatory compliance standards for safety, environmental impact, and quality assurance.
  • Collaborate with plant safety officers and regulatory agencies to ensure casting operations are in full compliance with safety and environmental regulations.
• Equipment Selection & Technology Integration:
  • Evaluate and recommend advanced casting technologies, equipment, and machinery for the corporate fleet to ensure optimal performance and cost-effectiveness.
  • Work with engineering teams to ensure new equipment or upgrades to casting lines are integrated smoothly into production operations with minimal disruption.
  • Stay ahead of industry trends, innovations, and emerging technologies, particularly in billet casting and related processes.
• Reporting & Strategic Collaboration:
  • Regularly report to senior management on the status of casting operations, highlighting key performance indicators, challenges, and opportunities for improvement.
  • Collaborate with senior leadership on strategic initiatives, such as capital investment projects, new product lines, and process redesigns.

• Skills & Knowledge:
  • In-depth knowledge of billet casting techniques and the associated machinery and equipment.
  • Strong understanding of aluminum casting processes, quality control procedures, and industry safety standards.
  • Proficiency in manufacturing process modeling, quality control systems, and performance monitoring.
  • Excellent leadership and team-building skills with the ability to influence and guide cross-functional teams.
  • Strong problem-solving skills and the ability to make decisions under pressure.
• Additional Competencies:
  • Ability to drive innovation and change in a corporate manufacturing environment.
  • Strong communication skills with the ability to present complex technical concepts to non-technical senior management and stakeholders.
  • Experience with ERP systems, casting process simulation tools, and other manufacturing software.

Preferred Skills:

• Experience with advanced casting technologies, such as high-pressure die casting.
• Experience in leading corporate-wide initiatives for process improvement and capital projects.
• Familiarity with lean manufacturing principles and Six Sigma methodologies.

Working Conditions:

• This role involves overseeing operations across multiple industrial sites, with occasional travel to various manufacturing plants.
• Exposure to industrial environments with high temperatures, molten metals, and heavy machinery.
• PPE requirements, including flame-resistant clothing, gloves, safety glasses, and hearing protection, may be necessary depending on the location.

 
Job Qualifications

• Must have at least 10+ years of high level production/operations related experience within the aluminum industry.  
• Must have extensive experience working with castings, preferably billet.
• Must have strong technical aptitude and history of leading process improvement initiatives, process optimization, continuous improvement, etc.
• Bachelor’s degree in Metallurgical Engineering, Materials Science, Mechanical Engineering, or a related field is a plus.
• Candidates willing to relocate to one of the plant sites in SC/KY are highly preferred. Relocation assistance will be offered.

With over 90 years' combined experience, NES Fircroft (NES) is proud to be the world's leading engineering staffing provider spanning the Oil & Gas, Power & Renewables, Chemicals, Construction & Infrastructure, Life Sciences, Mining and Manufacturing sectors worldwide. With more than 80 offices in 45 countries, we are able to provide our clients with the engineering and technical expertise they need, wherever and whenever it is needed. We offer contractors far more than a traditional recruitment service, supporting with everything from securing visas and work permits, to providing market-leading benefits packages and accommodation, ensuring they are safely and compliantly able to support our clients.