Production Manager - Smelter

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.

About the Role:

The Production Manager provides strategic and operational leadership across the smelter, with direct accountability for the Potroom, Casthouse, and Carbon departments (department managers report to this role). The role aligns process development and continuous improvement initiatives, ensures disciplined budget planning and execution, and drives excellence in safety, quality, delivery, cost, and people development. The Production Manager fosters a high‑performance culture grounded in integrity, operational excellence, and care for people, accelerating organizational improvement and sustaining results through the Alcoa Business System (ABS).

Key Responsibilities:

• Align process development initiatives across all smelter departments using validated methodologies and core operating standards.
• Establish and lead continuous improvement projects related to process enhancements, cost initiatives, business plans, accounting considerations, and industrial engineering studies.
• Accelerate organizational change by deploying ABS systems (e.g., A3 problem solving, Rules in Use, standardized work, industrial engineering/Toyota Production System techniques) to strengthen customer–supplier connections and eliminate waste.
• Identify and capture value‑stream opportunities in collaboration with all departments.
• Support production departments in developing and forecasting capital budgets and operating costs in partnership with the Plant Manager.
• Support development of annual operating plans and departmental budgets.
• Monitor performance against plan; implement corrective actions to achieve targets.
• Lead and develop the Potroom, Casthouse, and Carbon department managers; set expectations, provide coaching, conduct performance reviews, and build succession plans.
• Oversee skills development and performance management across departments.
• Promote a culture of accountability, inclusion, collaboration, and continuous learning aligned with company values.
• Lead or contribute to routine production meetings and provide clear performance updates, insights, and recommendations to site leadership.
• Ensure standardized work is maintained and continuously improved following changes.
• Assist, support, train, and challenge all levels of the organization to find opportunities and develop action plans to increase efficiency using the full complement of ABS systems and structured problem solving.
• Lead or support incident investigations and root‑cause analysis; ensure timely implementation and verification of corrective actions.
• Maintain accurate records, reports, and documentation in accordance with company and regulatory requirements.

Working Conditions:

• Heavy industrial smelter environment with exposure to high heat, noise, moving/rotating equipment, molten metal, and electrical hazards.
• Frequent presence on the production floor across Potroom, Carbon, and Casthouse.
• May require off‑shift work, weekend coverage, or on‑call availability to support operations and emergencies.
• Physical requirements: ability to stand/walk for extended periods, wear required PPE (including respirators where applicable).

Environmental Responsibilities:

• Ensure all operations adhere to environmental permits, regulations, and site standards.
• Drive continuous improvement to reduce environmental impacts (e.g., emissions control, waste reduction, responsible material management, and energy efficiency).
• Ensure teams follow procedures for emissions monitoring, waste handling, spill prevention/response, and material storage/usage, with accurate recordkeeping and training.

Safety Responsibilities:

• Champion a proactive safety culture; model safe behaviors and enforce safety policies, standards, and life‑critical rules.
• Partner with department leaders to identify hazards, assess risks, and implement engineered and administrative controls.
• Ensure effective use of standardized work, pre‑task risk assessments, lockout/tagout, contractor management, and verification practices.
• Confirm all employees receive required safety training, competency validation, and refreshers; lead safety communications and learning from events.

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:

Minimum Qualifications:

• 5+ years of supervisory experience in a smelter or manufacturing environment providing oversight to process and operations OR 7–10 years as a technical contributor with advanced process knowledge and demonstrated leadership. Demonstrated ability to lead teams within unionized workplaces, building trust, maintaining constructive relationships with union representatives, and effectively navigating contract provisions.4–6 years of process improvement and department management, including hands‑on involvement in budget development and execution.
• Knowledge of aluminum and/or casting processes.

Preferred Qualifications:

• Bachelor’s degree in an Engineering discipline or other technical field.
• Proven experience in continuous improvement and implementation of lean manufacturing methodologies (e.g., ABS, Toyota Production System).
• Demonstrated success deploying standardized work, A3 problem solving, and industrial engineering techniques across multiple departments.
• Experience leading multi‑department operations in a heavy industrial setting.

Skills and Competencies:

• Leadership & People: ability to influence, coach, and develop leaders; drive accountability and engagement; lead change effectively.
• Operational Excellence: strong command of process improvement, root‑cause analysis, lean tools, and standardized work; results‑oriented with disciplined follow‑through.
• Business & Financial Acumen: budgeting, forecasting, cost control, and DI savings rigor; data‑driven decision‑making.
• Safety & Environmental Stewardship: risk identification, control implementation, and compliance leadership.
• Collaboration & Communication: clear, timely communication; effective cross‑functional partnership; meeting facilitation and executive reporting.
• Technical Aptitude: familiarity with smelter unit operations (Potroom, Carbon, Casthouse), reliability concepts, and production systems.

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 applicants only. 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.