Smelter Reliability Engineer

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.


* Assist with implementation of REX ...