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Smelter Reliability Engineer

4 months ago

Newburgh, United States Alcoa Full time
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:

Alcoa Warrick is looking for a Reliability Engineer to be part of our Smelter team This professional will have the opportunity to refine a financial position of Warrick Operations by improving the reliability and cost to maintain assets. It will require a strategic focus on equipment to find repeat failures and eliminate the issues to root cause and optimize maintenance strategies and programs by incorporating predictive technologies. (Vibration, Infrared, MCA, Ultrasound, etc.) This position will partner with Smelting Engineering and Asset Management COE to deliver business results with the main customers being Smelting Maintenance and Operating departments and the Warrick Site Lead Team.

Major activities and key challenges
  • Identify long term opportunities for improvement focusing on equipment reliability.
  • Analyze OEE (Overall Equipment Effectiveness) data collected by Operations; use data to Pareto and help prioritize to identify and target equipment bad actors.
  • Analyze equipment CMMS (Computerized Maintenance Management System) performance data and equipment history to identity repetitive and/or costly failure occurrences.
  • Recognize and develop strategies to eliminate repetitive and major failures.
  • Apply sophisticated reliability-based tools and processes to investigate to Root Cause (RCA) equipment failures and provide recommendations for elimination, ensuring corrective actions are linked back to equipment strategies.
  • Facilitate Failure Modes Effects Analysis (FMEA) for critical equipment, identifying specific failure modes and corrective actions.
  • Define, develop (PMO) PM Optimization & Predictive (PdM) maintenance strategies / technologies / quality / frequency to provide the most cost-effective outcome for the business.
  • Review and optimize lubrication requirements, methods, and frequencies.
  • Identify knowledge gaps and act as a translator/trainer between the language of business (availability, MTBF, Downtime, Utilization, Root Causes, etc.) and language of the shop floor to both operations and maintenance.
  • "Champion" equipment/maintenance/failure data collection and recording standardization and integrity in the CMMS and appropriate systems.
  • Track cost savings on equipment and prepare single point lessons on savings to educate management on the value of the program.
  • Lead and facilitate implementation of REX (Reliability Excellence) program in coordination with Asset Management COE and Smelter REX Lead Team.
  • Lead Reliability Technicians in the implementation of Predictive (PdM) maintenance strategies / technologies.
What you can bring to the role:

Our values - act with integrity, operate with excellence, care for people & lead with courage - are at the foundation of everything we do. To be successful in this role and to play a part in our ongoing success we desire the following background:
  • Bachelor of Science degree in an engineering, technical field or equivalent experience with significant experience
  • Well-developed interpersonal, communication and teamwork skills.
  • Strong understanding and ability to quickly comprehend electrical and mechanical systems and failure modes.
  • Proven problem-solving using data.
  • Effective team leader and team member that energizes others.
  • Ability in influence business leaders, peers, and team members expertly with data, logic and presentation skills.
Preferred Qualifications:
  • 5+ years of heavy industry experience
  • PdM technology certifications in IR, UE, MCA - the professional will need to be level I in each of these technologies in 18 months; Level II in one technology.
  • Strong digital literacy. (MS Office, creating document templates, Creating Excel sheets with special formatting/tables, importing data/results, etc.)
What's On Offer:

At Alcoa, our care for people philosophy is backed by our excellent total rewards package that we provide our employees effective on your date of hire, such as:
  • 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
  • Work-life balance programs: flexible work scheduling, hybrid/remote working
  • Paid time off: 15 vacation days prorated in the 1st year based on hire date, 10 holidays including 1 flexible holiday of your choice, 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


*This benefit information applies to US based applicant sonly. Alcoa reserves the right to change plans at its discretion.

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About the Location

Alcoa "Warrick" based in Newburgh, Indiana just outside of Evansville, IN has been present in the lives of many families in our community for over 60 years. We've grown and we've matured together. Now we are looking for our next generation of Alcoans to bring us into the future. You can be one of them Join us and get ready to experience endless opportunities

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

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