Sr. Process Engineer - Dunkirk
- Precision Castparts Corporation
- Dunkirk, New York
- Full Time
Sr. Process Engineer - Dunkirk
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Full Time
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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
- 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
Status
Live
Position Details
Region
Americas
Country
United States of America
State / County
New York
City
Dunkirk
Division
Metals
Company
New Hartford/Dunkirk
Function
Engineering
Department
ENG-Materials/Process Engineering
Job profile
Process Engineer 3
Workday EEO Code
2 - Professionals
Workplace Type
On-Site
Position type
Full Time
FLSA / Overtime
Exempt
Union
No
Reason for opportunity
Backfill
Confidential Role
No
Anticipated start date
June 2026
Does this position require access to information or production processes subject to U.S. export control laws and regulations (such as the International Traffic in Arms Regulations (ITAR) or the Export Administration Regulations (EAR))?
To verify, go to the Location page for the hiring site in Workday and check the Location Attributes section in the middle of the page. If you have questions, consult the Site FCO.
Answering "Yes" to this question will populate an ITAR/EAR statement on the Job Posting, as well as a question verifying US Personhood on the Standard Application form.
Yes
Hiring Manager
Corey O'Connell/Wesley Abbatoy
External market data obtained?
No
Job Posting
The text input below will display to the candidate. Please pay attention to spelling/grammar.
Company Profile
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.
Job Description
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
- 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
Is relocation authorized?
Yes
Attach an additional document?
No
Compensation
Pay range will be visible in the job advertisement for states where we are required to disclose it
Pay Rate
Salaried
Bonus Program
Quarterly Cash Bonus
QCB Multiplier
2X
LTIP Eligible?
No
Please list the hourly rates or the annual salary range with no dollar signs.
Salary Minimum
92,000
Salary Maximum
138,200
Salary Currency
US Dollar (USD)
Relocation amount
10,000
Vacation (Hours)
120
Approvals
Further approvals required?
None
Pre-Application Knock Out Questions
Use pre-application knock out (Yes/No) questions?
Yes
How many?
1
The text input in each question below will display to the candidate. Please pay attention to spelling/grammar.
Pre-application knock out - Q1
Do you hold a bachelor's degree in Metallurgy Engineering or Materials Science?
Note: You can change the pass answer for each question on the 'Pre-application knock out' form on the 'Candidate Forms' tab.
Red Flag Questions
How many red flag questions?
None
Skill-related Questions
These questions allow the candidate to type a free text response to a skill-related question
No. of skill questions
None
Interview and Assessment Competencies
Competencies used for behavioral interview and/or PCC assessment
Number of interview competencies
None
Process Builder
Will an assessment be completed outside of the system?
Yes
What stage is it required?
Post interview 1
No of interview rounds
2
Owners
Requisition Owner
Local HR
Recruiter
Exp Hire HR Manager Brenda Lazipone
HR manager
Exp Hire HR Manager Dawn Clarry
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