Casthouse Operations Lead: Safety & Continuous Improvement

Alcoa Australia; Indiana; On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Competitive compensation package

401(k) with 6% employer match

Healthcare benefits (medical, Rx, dent

Vision, FSA/HSA

Hybrid/remote work options (for some/1

Job summary

Alcoa Warrick in Newburgh, IN seeks a Casthouse Superintendent to lead daily operations on the production floor, directing four supervisors and supporting hourly workers in a union environment. The role focuses on safe, reliable production from molten receipt to finished shipment, with a Monday–Friday core schedule and potential for cross-shift coverage.

You will drive safety, quality, and cost performance while coordinating with maintenance and other functions to sustain output and continuous

Qualifications

• Significant leadership or supervisory experience in manufacturing, smelting, casting or heavy industrial environments.
• Experience leading salaried supervisors and working with hourly employees in a union environment.
• Hands-on understanding of Casthouse or related aluminum operations.
• Demonstrated commitment to safety, operational excellence, and continuous improvement.
• Strong planning, organization, and decision-making skills.
• Clear communication, coaching and employee-development abilities.
• Familiarity with ISO systems, Lean Manufacturing or Six Sigma.
• Knowledge of casting processes, chemistry calculations, scrap utilization, skim and dross management, environmental regulations.

Responsibilities

• Lead daily Casthouse operations with clear priorities for safety, production, quality, cost, customer requirements and environmental and operational compliance.
• Build a strong safety culture through visible floor leadership, routine audits, hazard identification, employee engagement, and accountability for safe practices.
• Coach and develop frontline supervisors and employees, strengthening communication, teamwork, and performance across shifts.
• Monitor production and material flow, troubleshoot issues, and align staffing and resources to maintain reliable output.
• Partner with Maintenance to prioritize repairs, coordinate preventive maintenance, reduce downtime and pursue continuous improvement.
• Maintain operating discipline and quality-system compliance, including ISO 9001 requirements; support department administration and serve as acting Casthouse Manager when needed.

Skills

Leadership

Supervisory experience

Casthouse operations

Safety culture

Continuous improvement

Communication

ISO 9001

Lean Manufacturing

Six Sigma

Planning & decision-making

Job description

Alcoa Warrick in Newburgh, IN seeks a Casthouse Superintendent to lead daily operations on the production floor, directing four supervisors and supporting hourly workers in a union environment. The role focuses on safe, reliable production from molten receipt to finished shipment, with a Monday–Friday core schedule and potential for cross-shift coverage.

You will drive safety, quality, and cost performance while coordinating with maintenance and other functions to sustain output and continuous