The Senior Development Metallurgist conducts research develops processing techniques, and other technologies with a focus on the development of new products, services and markets.  The position will also research and propose new production equipment, procedures, and methods to automate, improve, and/or scale-up existing processes.

Perform metal manufacturing processes employing techniques appropriate to the task to maintain or improve the Company's competitive market position.  Duties may include utilizing a broad range of equipment currently used in Development or Manufacturing.

• Identify and develop novel approaches to optimize metal manufacturing processes. (Including for example:  alloying, casting, deformation, heat treatment and analytical characterization)
• For new development projects, conduct experiments, perform analytical characterization activities, gather data, analyze data, establish material property relationships, draw conclusions, and document concise technical reports with clear recommendations.
• Apply solid scientific understanding to the innovation and development of novel materials and processes.  Drive analytical data gathering and processing for data-based decision making.
• Scale and validate new product processes in conjunction with the R&D team and operations.
• Ensure any sub-contract vendors are appropriately evaluated and selected.
• Identify and drive continuous improvement.  Apply solid scientific understanding to the innovation and development of novel materials and processes especially relating to metal product manufacturing.
• For approved Product Development follow the Stage-Gate development process.  Ensure as part of the design iteration loop, failure analysis of development products and re-design are routinely performed.
• Support identifying and evaluating new analytical technology relevant to current and future products.
• Make recommendations for capital equipment purchase. Evaluate metal processes and identify risk areas. Understand liabilities, yield, environmental and health & safety.
• Maintain awareness of trends and new developments in metallurgy through membership in professional societies and technical readings.
• Support AMG Sales and Marketing in new product development.
• Provide technical reports to customers for new qualifications and on-going technical analyses.
• Support Sales and Marketing by participating in meetings, conference calls etc. when direct communication with customers requires Technical input. This may also encompass technical seminars, trade shows, exhibitions etc.
• Provide guidance on the potential viability of new materials and their manufacturability.
• Be available to comment on the R&D Prototype Schedule in conjunction with Sales, Logistics and Manufacturing.

Position Summary:

• Lead the associates in your area through coaching, engagement, communication, morale building and teaming. Be the Leader and Coach not the boss.
• Engage, coach and train your team to continuously improve the Safety, Quality, Delivery and Cost goals of the business
• Drive action where ever needed to resolve urgent issues
• Be a key leader in implementation of the Operating Excellence (OOE) process
• Escalate actions needed to achieve OOE implementation goals
• Team with Area Managers, Union Stewards, Support personnel and other Leadership to constructively solve operational issues that both meet the business goals and the intent of the current contract

Tasks and Responsibilities:

• Supervise Metallurgists, Met lab operations, lab technicians, and Pyros.
• Conduct studies of metals and alloys to determine their physical characteristics for manufacturing purposes or determine compliance with manufacturing specifications and standards
• Apply knowledge of metallurgy to recommend engineering and manufacturing changes to attain design objectives in the most economical manner possible
• Consult with engineers to develop methods of manufacturing at minimum costs
• Work with customers to make sure their expectations are being met and exceeded
• Conduct failure analysis
• Provide support to Sales and Purchasing departments - Interpreting standards, proposing materials and processes, qualifying new suppliers, resolving material or quality issues, etc.
• Responsible for communicating metrics and ensuring understanding and ownership at the production team level
• Prioritize production schedules based on product introduction, equipment efficiency and materials supply
• Team with support groups such as EHS, Quality Assurance, Engineering and Planning to escalate and improve urgent issues as well as drive continuous improvement
• Provides all subordinates with constant communication, guidance, coaching and support necessary to perform their jobs effectively and accurately
• Works with the Safety Department to monitor safety compliance and to review and plan for special requirements on incoming jobs
• Leads regular audits of the department to ensure proper safety and environmental practices are being followed
• Uses progressive discipline to correct and manage major violations of company policies, and the Collective Bargaining Agreement (e.g., fighting, sabotage, etc.)
• Investigates incidences of, and initiates corrective actions to, improper conduct on the floor or major violations of company policies or the CBA
• Accountable for heat treat department organization by driving 5S deployment
• Assure the proper training of all department personnel

• Ability to understand and follow applicable company and regulatory safety and environmental procedures
• Ability to understand and correctly utilize appropriate PPE equipment as required
• All other duties as assigned by Management

Responsible for product quality assessment and improvement. Works with Process Engineers, Operations management and employees to improve the product quality through standard practices, process control and understanding customer requirements. Works with Technical Service Engineers to evaluate, communicate, and translate customer requirements to miss practices. Provides technical assistance and quality support to the Quality and Operations management group.

Role and Responsibilities

Position requires solid metallurgical skills and abilities to provide technical advice and direction to the organization.

Ensures that technical standards and work instructions to ensure product quality and NPS requirements are implemented and followed.

Interface with the GM Quality as well as Technical Service Engineers to translate customer quality requirements to the mill, gather data and analyze any trials

Interface with the GM Quality and Applications Engineer to translate customer quality requirements to mill practices, routings and setups for satisfactory production.

Interface with the Operating Group, including Management, Process Engineers and hourly employees to make real time decisions on mill control, measurement and operating practices for satisfactory production.

Evaluate product quality of material at all stages, incoming product, internal production and disposition as prime, rework or reclass.

Observe and measure product quality at outside processing units as necessary to evaluate product quality and disposition product

Collect and analyze data for product (and process) quality improvement, communicate necessary changes to process, practices or measurement.

Works with the Commercial Group to fully address customer technical inquires and formulate an appropriate response to the customer.

Will monitor and coordinate all aspects of the Materials Department required to meet the quality and scheduled delivery of product, while constantly exploring and engaging in continuous improvement activities.

ESSENTIAL FUNCTIONS:

• Direct, supervise and coordinate all technical and production activities associated with rod, wire and strip manufacture, including melting, casting, welding, rolling, slitting, drawing, annealing, heat treating.
• Through supervisors and team leads, maintain production schedule to insure on-time deliveries and highlight capacity issues.
• Instruct Process Engineering on priorities for ensuring effective engineering support on capacity, quality or cost concerns.
• Work with Materials Process Engineering on process development for new products (alloys), continuous improvement and cost reductions.
• Develop the department’s capabilities through modification or procurement of equipment, training of staff, or hiring of qualified personnel.
• Responsible for establishing and tracking key business performance measures.
• Involved in the development of new alloys and processes in conjunction with R&D as required.
• Adhere to all company and human resource policies and procedures fostering a strong and dedicated work ethic resulting in continued productivity and quality improvements.
• Maintain a safe and clean work environment continuing the 5S culture.
• Evaluate performance, develop and motivate production personnel through annual reviews and regular feedback, coaching, and training as necessary to broaden worker skillsets and flexibility within the department.