Senior Materials Process Engineer - ELYSIS

About the position

Key Activities / Responsibilities

• Develops and implements process improvement programs focused on reducing scale-up, operational, and manufacturing risks associated with critical equipment and production processes.
• Leads process engineering projects by defining objectives, developing execution plans, and applying engineering analysis to improve process capability, stability, efficiency, and throughput across pilot and commercial operations.
• Provides data-driven recommendations for process optimization, equipment performance, production readiness, and operational reliability to support successful deployment and sustained operation of Elysis technology.
• Supports the development and refinement of process specifications, operating procedures, equipment requirements, and control strategies through continuous improvement initiatives and analysis of process performance data.
• Apply sound engineering principles and a hands-on approach to troubleshoot process challenges, optimize production performance, and support manufacturing operations in laboratory, pilot, and commercial environments.
• Utilizes root cause analysis, statistical methods, and problem-solving tools to identify, investigate, and implement sustainable corrective actions for process, equipment, quality, and production-related issues.
• Identifies and leads initiatives that improve process efficiency, yield, reliability, product quality, capacity utilization, cost performance, and operational consistency.
• Collaborates with operations, maintenance, quality, R&D, suppliers, and external partners to ensure successful execution of process improvement projects while managing scope, schedules, budgets, and deliverables.
• Establishes and monitors key process performance indicators (KPIs), analyzes production data and trends, and develops actionable recommendations to improve process control and operational performance.
• Documents, communicates, and standardizes process improvements through technical reports, operating procedures, work instructions, presentations, and knowledge-sharing activities to ensure long-term process sustainability and organizational learning.

Mobility

About You

Diversity: Be Part of an Unprecedented Partnership

About the Location

• Every day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSIS™, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process– a revolution to the aluminum industry!
• 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 gssrecruiting@alcoa.com.
• 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!