Sr. Process and Product Technology (PPT) Technician - Casting

Overview / Job Summary

  • Aleris is a global leader in the manufacture and sale of aluminum rolled products, with approximately 14 facilities in three geographically aligned business units in North America, Europe and China. We serve a variety of end-use industries, including aerospace, automotive, defense, building and construction, transportation, packaging, and consumer goods.
  • Our Lewisport plant is seeking to add a Sr. Process and Product Technology Technician to its team. The purpose of this role is to improve and transfer knowledge of all dedicated processes, responsible for process improvement, support product trial, support startup of new investments and processes and assist in the effective and efficient functioning of the Quant lab.

Responsibilities Include

Purpose of the position:

  • Coordinate efforts between PPT, Operations, Maintenance and Product Technology teams to help Aleris achieve its safety, ABS, quality, throughput and uptime goals
  • Provide expertise, practical and administrative support to the PPT Engineers to facilitate efficient and effective execution of the ongoing process and product improvement and development projects
  • Coach and mentor the entry level PPT technicians in the best practices of casting, metal cleanliness, quant lab procedures and process control tools.
  • To assist the PPT and PT Team in organizing, running and administrating product/process trials.

Process Activities

  • Communication/escalation of product/process related activities and concerns
  • Responsible for the definition of all process settings which are used to ensure stable, robust, and efficient processes that deliver the required product quality.
  • Develop Standard Operating Practices (SOPs) to ensure best practices.
  • Identify and lead capability and quality improvement projects taking into account safety, cost, and environmental constraints, as well as the effects on subsequent processes.
  • Initiate, verify, and validate process changes within primary assigned area of responsibility using the Management of Change process.
  • Assist production, when necessary, to perform root cause analysis or troubleshooting in a structured way to address process or product nonconformities.
  • Assist with development and implementation of corrective actions in relevant processes resulting from claims and nonconformities.
  • Partner with production, maintenance, and engineering in his or her operational area.
  • Responsible for the setup of a system of process control for all relevant subprocesses including the Quant Lab to ensure stable performance in time.
  • Provide second line technical support on installation projects.
  • Takes initiative in continuous learning and development within functional area.
  • Partner with R&D on the industrialization of new products.
  • Support PT group the qualification of raw material and ingot suppliers.
  • Lead the implementation and sustainment of Aleris Process Control (APC) in the assigned area.

Trial Support

  • Lead technical events to improve the capability and capacity of the process and the equipment.
  • Make practical arrangements with the production planning to enable smooth trial runs
  • Follow up on trials on other production installations in the plant or at Tollers, occasionally requiring a flexible schedule
  • Coordinate and assist in the successful realization of the necessary sampling on internal and external trial material
  • Prepare samples for shipping to customers or third parties
  • Manage files and sample archive and guarantee traceability in case of projects, claims, and customer questions
  • Provide accurate result reporting to all areas.

Operational Support

  • Provide metallurgical advice and more-formalized training on metallurgical topics as needed to advance employee understanding of Casting
  • Assist Production and Maintenance personnel in day-to-day problem solving of process issues.
  • Recommend, evaluate, and initiate improvements to Casting Processes, in the areas of Quality, Process Control, and Cost Control.
  • Understand casting parameters along the lines of alloys and casting recipes to help stabilize the quality


  • Guarantee reproducible results by developing job instructions for the operators and lab technicians
  • Training of layered process audits and audit coaching for supervisors and above
  • Seek to implement and teach best practices within Lewisport

Required Qualifications

  • In depth understanding of the Aluminum casting process
  • 8+ years of Casting experience
  • Experience in chemical analysis using a Quantometer
  • Knowledge of the production installations in the plant to enable a safe and efficient follow up of trials
  • Some technical training in a related field
  • Proficient in Excel, Word and Power Point required

Preferred Qualifications

  • Certified LSS Green belt would be an asset
  • Knowledge of ISO 9001 and TS 16949 principles preferred
  • Knowledge of plant IT systems and manufacturing system preferred
  • Experience with automotive customers preferred

Aleris is an equal opportunity employer and supports diversity in the workplace. Qualified applications will receive consideration for employment without regard to their race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran. Our HR teams will reach out to the applicants who meet the qualifications and are most closely aligned with requirements of the position.

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