Principal Foundry Process Engineer - Orthopaedics

Overview

Johnson & Johnson is seeking a Principal Foundry Process Engineer to provide senior technical leadership for end-to-end foundry manufacturing processes in a regulated orthopedic implant manufacturing environment. The role focuses on investment casting processes including wax injection, ceramic shell creation, casting, post-casting finishing, porous coating, and related interfaces.

Responsibilities

• Act as the senior technical process owner for key foundry operations, including wax injection, ceramic shell creation, casting, post-casting finishing, and porous coating.
• Lead process strategy for scrap reduction, process capability, standardisation and long-term process stability.
• Develop and improve process control strategies for wax injection, shell/ceramic moldroom slurry and environmental control, pour and solidification, casting finishing, porous coating, and non-destructive testing interfaces.
• Use statistical analysis, process capability studies, design of experiments, control charts, defect Pareto analysis and real-time process data to identify instability and drive durable corrective actions.
• Lead technical problem solving for recurring scrap, deviations, yield loss, rework, process variability and product-family-specific manufacturing issues.
• Provide technical direction for process development, process characterisation, validation, equipment evaluation, material evaluation, specifications and operator instructions.
• Partner with quality, validation and operations teams to assess process changes, material changes, equipment changes and parameter changes through appropriate risk management and validation pathways.
• Support non-conformance investigations, corrective and preventive actions, audit actions and technical reviews by providing process evidence and process control rationale.
• Create and maintain process documentation, playbooks, response flow charts and training material for critical foundry processes.
• Coach process engineers, technicians, operations teams and partner functions to build foundry technical capability and improve troubleshooting effectiveness.

Qualifications & Experience

• Master's degree or equivalent in Engineering, Materials Science, Metallurgy, Manufacturing Engineering, Mechanical Engineering or a related discipline.
• Significant experience in process engineering, foundry / investment casting, regulated manufacturing, high-complexity manufacturing or equivalent process leadership roles.
• Demonstrated experience leading technical problem solving, process validation, scrap reduction, process capability improvement and cross-functional manufacturing projects.
• Foundry, investment casting or precision casting experience is strongly preferred.
• Experience using structured problem-solving methods, statistical analysis, design of experiments, process capability tools and Lean Six Sigma is desirable.

Skills & Capabilities

• Deep understanding of investment casting or foundry process steps, including wax, ceramic shell, molten metal pouring, casting finishing, porous coating and downstream inspection / finishing interfaces.
• Strong process excellence capability, including root cause problem solving, A3 problem solving, design of experiments, statistical analysis, process capability and value stream improvement.
• Ability to combine data analysis with hands-on process observation to understand process risk and drive practical improvements.
• Strong stakeholder leadership across operations, quality, validation, asset reliability, project engineering, manufacturing innovation, suppliers and site leadership.
• Ability to mentor engineers and build technical capability across the manufacturing organisation.

Don't miss this exceptional opportunity to join a world-class company and make a lasting impact. Apply now and be part of our ambitious team.

Benefits

• Competitive base pay with additional benefits including annual bonus, depending on location and performance.
• Vacation, parental leave, bereavement leave, caregiver leave, well-being reimbursement, and programs supporting financial, physical and mental health.
• Service anniversary recognition and access to multiple insurance plans where eligible.