Foundry Manager
Foundry Manager
Location: Anniston, Alabama
Industry: Industrial Manufacturing
Position Summary
The Foundry Manager is responsible for the safe, efficient, and cost‑effective operation of a high‑volume iron foundry located in Anniston, Alabama. This role provides leadership across all foundry processes-including melt, sand systems, molding, coremaking, pouring, shakeout, and finishing-to ensure consistent production of high‑quality ductile and/or gray iron castings used in municipal water and wastewater infrastructure products.
The Foundry Manager owns performance across Safety, Quality, Delivery, Cost, and People (SQDCP) and drives operational excellence, continuous improvement, and workforce development while ensuring compliance with all regulatory and environmental requirements.
Key Responsibilities
Safety & Environmental Leadership
- Lead and reinforce a world‑class safety culture across all foundry operations, with particular focus on molten metal handling and high‑risk processes
- Ensure compliance with OSHA, EPA, and applicable state and local environmental regulations
- Lead safety incident investigations, root cause analysis, and corrective action implementation
- Promote proactive risk assessments, preventative maintenance, and safe‑work practices
Foundry Operations & Production
- Direct daily foundry operations including:
- Iron melting (cupola, induction, or equivalent systems)
- Sand preparation, control, and reclamation (green sand and/or no‑bake systems)
- Molding and coremaking
- Pouring, cooling, shakeout, cleaning, and finishing
- Execute production plans aligned with customer demand, schedules, and inventory targets
- Improve production throughput, casting yield, and equipment uptime
- Control operating costs including labor, scrap, rework, energy, alloys, sand, and consumables
Quality & Metallurgical Control
- Ensure proper metallurgical practices, iron chemistry control, and casting integrity
- Drive reduction of casting defects such as shrinkage, porosity, inclusions, erosion, and misruns
- Partner with Quality and Engineering teams on defect analysis and corrective actions
- Support internal and external audits, certifications, and customer quality requirements
Leadership & Workforce Development
- Lead, coach, and develop supervisors, engineers, and hourly foundry employees
- Foster accountability, engagement, and teamwork across multiple shifts
- Build strong succession plans and develop technical capability within the foundry
- Support labor relations and workforce planning aligned with company values
Maintenance, Engineering & Continuous Improvement
- Partner with Maintenance to ensure reliable operation of furnaces, molding lines, sand systems, and material handling equipment
- Support capital planning, equipment upgrades, and automation initiatives
- Lead Lean manufacturing, Six Sigma, and continuous improvement efforts
- Track and improve KPIs such as safety metrics, OEE, yield, cost per ton, and on‑time delivery
Qualifications & Experience
Required
- Bachelor's degree in Metallurgical Engineering, Materials Science, Mechanical Engineering, Manufacturing Engineering, or related discipline
- 7+ years of foundry experience in iron casting operations
- 3+ years of leadership experience in a foundry or heavy industrial manufacturing environment
- Working knowledge of:
- Iron melting and metallurgy
- Sand systems and molding processes
- Casting defect analysis and corrective actions
- Foundry safety and environmental requirements
Preferred
- Experience in ductile iron and/or gray iron foundries
- Experience producing municipal water and wastewater infrastructure products
- Experience leading multi‑shift, high‑volume foundry operations
- Lean, Six Sigma, or continuous improvement certifications
- Experience working in a unionized manufacturing environment
Key Performance Indicators
- Safety performance and regulatory compliance
- Casting yield, scrap, and rework reduction
- On‑time delivery and throughput
- Cost per ton and operational efficiency
- Employee development, engagement, and retention
Why This Opportunity
This role offers the opportunity to lead a legacy iron foundry supporting critical municipal infrastructure while driving safety excellence, modernization, and operational performance in a high‑impact manufacturing environment.
FAQs
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