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Graduate Opportunity

Project Assistant: Manufacturing Quality

Manufacturing/Metallurgy/Software. 12 Week Internship.

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This is a 12-week paid internship opportunity as part of the WMG Internship Programme. This position is suitable for recent graduates who are looking for an internship that may lead into a job offer.

The role involves critical investigation of key aluminium casting production processes within the foundry and machine shop to improve quality, reducing defects and identify preventative solutions, advising the company of steps to take with their process moving forward.

The internship is based at the client company site in Wednesbury, and you will be working closely with the AluCast team, gaining first-hand experience in a manufacturing business; as part of the program, you will also benefit from weekly supervision and support by a WMG expert, throughout the duration of the project.

Should you be successful during the internship, there may be opportunity for a full-time position at the end of the 12-week period.

About the company:

Alucast Ltd is an award-winning aluminium casting foundry supplying fully machined components to the UK market. Alucast has experience of supplying components for almost every industrial sector, using the manufacturing methods of Sand casting, Gravity Die (Permanent Mold) casting, Low pressure casting and High Pressure Die Castings.

Duties and responsibilities

You will lead a project to improve quality for the company’s production processes. This will include documenting the existing processes in detail, capturing data on the activities, and conducting root cause analysis. Main activities will include:

  • Pareto Analysis to identify 3 key product parts for investigation
  • Understanding and documenting the current process
  • Develop data collection methodologies on current activities to identify a pattern and trend in rejected components.
  • Organising several trials and experiments to identify and reviewing the potential root causes.
  • Analysing Magmasoft simulations, to identify potential variables that may cause defects
  • Generating short term corrective actions to improve the process and piloting them
  • Setting out recommendations and analysing cost viabilities of longer-term improvements to the process to prevent recurrence of rejects.
  • Developing own facilitation skills

Skills and experience


  • A Bachelor’s or Master’s degree in a relevant engineering or manufacturing degree (or equivalent) completed at the time of the application.
  • Analytical thinker with a practical approach to problem solving
  • Ability to be flexible to work in different environments
  • Knowledge of continuous improvement tools, such as process mapping, data collection, root cause analysis, solution generation and control plans
  • Organised and highly motivated with a focus on results
  • Confident communicator, able to effectively communicate with staff at all levels
  • Ability to work under pressure and to tight deadlines
  • Self-motivated, driven, and proactive
  • Able to relocate to Alucast client site


  • Knowledge of Lean Six Sigma, specifically statistical process control
  • An understanding and appreciation of Aluminium metallurgy
  • Practical laboratory or engineering experimentation experience
  • Experience in Simulation software such as FEA

Application Guidelines

This role is part of the WMG Internship Programme. Unfortunately, we are unable to consider you for this internship if you are applying for this to count towards a work placement as part of your studies.

This role is open to students, graduates, postgraduates and PhD Students who are:

  • Based in the UK 
  • Eligible to work in the UK 
  • Available to work 36.5 Hours per week (Full time)

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Opportunity Overview

  • Deadline: August 28th, 2022
  • Starting: October 2022
  • Starting Salary: Competitive + benefits
  • All grades
  • Wednesbury (Sandwell)
    (Show map)

Preferred Disciplines...

  • Electrical
  • Manufacturing
  • Materials & Minerals
  • Materials Science
  • Mechanical
  • Metallurgy
  • Software

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