Furnace Process Engineer at IMC-Metalsamerica LLC

Description

 We are seeking a highly capable, degreed Materials, Chemical, Metallurgical, or Mechanical Engineer with a strong background in process engineering to join our team in a demanding copper foundry environment. This hands-on, production-focused role serves as the company’s Subject Matter Expert (SME) for all furnace and upcast technology, including cooler bodies and furnace controls. The Furnace Process Engineer will lead furnace process improvements, reliability, and system optimization to ensure peak melting and casting performance. The ideal candidate is a practical problem-solver with deep technical expertise, a proactive mindset, and a strong, consistent presence on the production floor. 

Essential Duties & Responsibilities

· Serve as the Subject Matter Expert for furnace and upcast technology, including cooler bodies and furnace controls.

· Promote and lead a safety-first mindset, ensuring all furnace systems and improvements support a safe work environment.

· Own and maintain process parameters for melting and casting systems; ensure they are documented, optimized, and adhered to.

· Work closely with operations and maintenance to optimize performance, reduce downtime, and improve throughput.

· Lead hands-on troubleshooting and problem resolution for furnace systems, including mechanical, thermal, and control-related issues.

· Partner with Maintenance to conduct root cause failure analyses and implement long-term corrective actions.

· Support and lead commissioning of new furnace systems and major repairs.

· Identify and implement process improvements using structured problem-solving and Lean principles.

· Create and maintain mechanical drawings, equipment specifications, SOPs, and job plans.

· Contribute to capital project development, execution, and commissioning.

· Develop and deliver training for operators and technicians on furnace operations, troubleshooting, and process control.

· Assist with spare parts strategy development and ensure specification integrity.

· Track and analyze downtime, process data, and costs; provide technical justification for improvements.

· Actively participate in plant continuous improvement and reliability initiatives.

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Preferred Skills & Competencies

· Experience with thermal systems, foundries, material handling, hydraulics, pneumatics, and mechanical design.

· Familiarity with PLC logic review and basic programming for furnace control systems.

· Understanding of copper metallurgy and the effects of process variables on product quality.

· CAD proficiency (AutoCAD, SolidWorks) for mechanical layouts and modifications.

· Working knowledge of CMMS and spare parts management systems.

· Familiarity with ERP systems (preferably NetSuite).

· Strong communication and interpersonal skills, with the ability to work effectively across departments and all levels.

· Organized, data-driven, and able to manage multiple priorities in a production-critical environment.

Requirements

Qualifications:

· Bachelor’s Degree in Materials, Chemical, Metallurgical, or Mechanical Engineering (BS) from an accredited engineering institution.

· Associate or engineering technology degrees will not be considered.

· 3+ years of experience in an industrial, foundry, or heavy manufacturing environment (copper or metals preferred).

· Demonstrated experience with mechanical systems, material flow, thermal processes, and equipment reliability.

· Familiarity with induction furnaces, upcasting processes, and related equipment.

· Ability to interpret mechanical, electrical, and process control schematics.

· Experience in root cause analysis, process control, and continuous improvement methodologies.