Casthouse Process Lead

Alcoa; Massena Springs (NY); On-site; USD 112,000 - 167,000; Full time

Benefits offered by this job

401(k) match

Healthcare

Paid time off

Job summary

Alcoa in Massena, NY is seeking a Casthouse Process Lead to drive process engineering initiatives across casthouse operations. You will lead safety, quality, reliability, and productivity improvements while partnering with operations, maintenance, quality and engineering teams to deliver sustainable solutions.

The role requires a Bachelor's in engineering, strong data analysis and process control knowledge, and experience leading projects in manufacturing or metals.

Qualifications

• Bachelor's degree in Chemical, Mechanical, Electrical, Metallurgical, Materials, Industrial, or a related engineering discipline.
• Demonstrated ability to lead engineering projects, perform structured problem solving, analyze process data, and implement sustainable process improvements.
• Strong knowledge of process control, quality systems, continuous improvement methodologies, risk assessment, and management of change.
• Ability to effectively communicate technical information and influence stakeholders across operations, maintenance, quality, leadership, customers, and suppliers.
• Progressive engineering experience in manufacturing, metals, casting, or a similarly complex industrial environment preferred.
• Experience providing technical leadership through project leadership, mentoring, coaching, or supervision preferred.

Responsibilities

• Lead Casthouse process engineering priorities and continuous improvement initiatives that improve safety, quality, reliability, throughput, cost performance, and customer satisfaction.
• Drive cross-functional engineering projects from concept through implementation, standardization, and long-term sustainment, ensuring measurable business results.
• Analyze process, production, quality, and equipment-performance data to identify root causes, solve complex problems, and implement sustainable improvements.
• Develop and optimize operating practices, process controls, specifications, and technical solutions that support plant objectives and key performance indicators.
• Partner with operations, maintenance, quality, and engineering teams while providing technical leadership, coaching, and training to engineers, technicians, and operators.
• Support the introduction of new technologies, equipment, and products while maintaining robust quality systems, operating standards, and performance reporting processes.

Skills

Engineering leadership

Process engineering

Data analysis

Stakeholder communication

Education

Bachelor's degree in Chemical/Mechanical/Electrical/Metallurgical/Materials/Industrial engineering

Job description

Shape Your World

At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

Shape Your World

At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

At Alcoa, you’re an essential part of our purpose: to turn raw potential into real progress. This is an opportunity for you to bring your wealth of experience to the team and help shape the future of sustainability with world-changing innovations and low-carbon technologies. You have the power to shape things to make them better.

About the Role

Are you passionate about solving complex technical challenges, leading process improvements, and driving operational excellence? Join our team as a Casthouse Process Lead, where you'll play a critical role in optimizing safety, quality, reliability, productivity, and customer performance across our Casthouse operations.

In this role, you'll serve as the technical leader for process engineering initiatives, partnering with operations, maintenance, quality, and engineering teams to deliver sustainable improvements and innovative solutions. You'll have the opportunity to lead impactful projects, influence plant performance, and help shape the future of our manufacturing processes.

• Lead Casthouse process engineering priorities and continuous improvement initiatives that improve safety, quality, reliability, throughput, cost performance, and customer satisfaction.
• Drive cross-functional engineering projects from concept through implementation, standardization, and long-term sustainment, ensuring measurable business results.
• Analyze process, production, quality, and equipment-performance data to identify root causes, solve complex problems, and implement sustainable improvements.
• Develop and optimize operating practices, process controls, specifications, and technical solutions that support plant objectives and key performance indicators.
• Partner with operations, maintenance, quality, and engineering teams while providing technical leadership, coaching, and training to engineers, technicians, and operators.
• Support the introduction of new technologies, equipment, and products while maintaining robust quality systems, operating standards, and performance reporting processes.

What you can bring to the role

• Bachelor's degree in Chemical, Mechanical, Electrical, Metallurgical, Materials, Industrial, or a related engineering discipline.
• Demonstrated ability to lead engineering projects, perform structured problem solving, analyze process data, and implement sustainable process improvements.
• Strong knowledge of process control, quality systems, continuous improvement methodologies, risk assessment, and management of change.
• Ability to effectively communicate technical information and influence stakeholders across operations, maintenance, quality, leadership, customers, and suppliers.
• Progressive engineering experience in manufacturing, metals, casting, or a similarly complex industrial environment preferred.
• Experience providing technical leadership through project leadership, mentoring, coaching, or supervision preferred.

What we offer

• Competitive compensation packages, including pay-for-performance variable pay, recognition and rewards programs.
• 401(k), employer match up to 6%, additional employer retirement income contribution (no vesting period)
• Healthcare benefits: medical, Rx, dental, vision, flexible spending account, health savings account (generous employer contribution), life and accident insurance
• Paid time off: 15 vacation days prorated in the 1st year based on hire date, 12 paid holidays, 7 illness days, Care for Family leave up to 40 days, up to 5 bereavement days, maximum of 30 jury duty days, and up to 10 days annual training for military leave

Base Salary: 111,800 - 167,400 USD annually

Total rewards packages listed, including base salary and bonus eligibility, applies to US based applicants only. Actual salaries will vary and will be based on a range of factors, including a candidate’s qualifications, skills, and competencies in conjunction with multiple components of the Employee Total Rewards Package. Alcoa reserves the right to change plans at its discretion.

About the Location

Our Massena facility in New York State, established in 1902, is home to the longest continuously operating smelter in the world. Located on the St. Lawrence River, Massena, NY is the center for commercial, industrial, and manufacturing success in St. Lawrence County. Massena’s caring sense of community, affordable cost of living, and extremely low-cost locally supplied energy, coupled with four public and private universities nearby, make Massena a great place to call home. And within a two hour drive (or less) are cosmopolitan and historic Montreal and Ottawa, Canada to the north, and to the south are the tall, beautiful views of Adirondacks and within it is Lake Placid The Olympic Village.

We are values led, vision driven and united by our purpose of transforming raw potential into real progress. Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate.

As a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person’s gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate.

If you have visited our website in search of information on U.S. employment opportunities or to apply for a position, and you require an accommodation, please contact Alcoa Recruiting via email at [e-mail].

This is a place where you are empowered to do your best work, be your authentic self, and feel a true sense of belonging. Come join us and shape your career!

Your work. Your world. Shape them for the better.

Application close date is: 28 September 2026, however Alcoa reserves the right to change this date at its discretion.