Senior Materials Process Engineer - ELYSIS

Alcoa•New Kensington, PA

1d•Onsite

About The Position

The Senior Materials Process Engineer will use their wide breadth of knowledge and expertise in ceramic materials and processes to lead research and development efforts associated with technical readiness level advancement of a ceramic process used to produce proprietary and novel electrodes for the Elysis smelting process. This role also serves to be the technical liaison, providing data-based decisions, guidance, and support to Elysis electrode production and industrialization teams. This role will report to Elysis R&D management.

Requirements

Degree in Materials Science & Engineering, Ceramics Engineering, or Chemical Engineering.
1-5 years of relevant work experience related to the development of ceramic materials or processes preferred.
Demonstrated knowledge in ceramic processing, processing equipment and process scale-up experience.
Proven project execution and management skills.
Strong aptitude in physical, chemical, and thermal material property characterization methods and analysis.
Experience working in collaborative, results driven, fast-paced team environments.
Strong communication, organizational and analytical skills for data management, analysis, and results presentation.

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.