Lead Engineer Metallurgy

JOB PURPOSE

The Lead Engineer - Metallurgy is responsible for establishing and maintaining metallurgical governance across Casthouse operations, with a focus on continuous process enhancement. This includes oversight of metallurgical parameters and quality control for a diverse product portfolio—such as, and not limited to standard ingots, sows, foundry alloys, billets, and slabs. The role supports production teams by integrating metallurgical expertise into quality assurance frameworks and process optimization initiatives, ensuring conformance to customer specifications while driving improvements in throughput, resource efficiency, and cost-effectiveness.

RESPONSIBILITIES

2.1 Action the Environment, Health & Safety (EHS)

The Job holder is accountable for delivering a safe work environment includes:

• Ensuring that all work practices follow Sohar Aluminum’s Environment, Health and Safety policies and procedures
• Performing and managing equipment and workplace cleaning and organization to ensure excellent housekeeping and safety standards
• Delivering clear, actionable EHS review reports. Executing the necessary follow-up action
• Working within the EHS policy framework and providing relevant EHS data/info about the process to key stakeholders
• Contributing to the development of the EHS systems: undertake root cause analysis; review the EHS plan and formulate proposals for improvement; undertake projects to drive excellence in EHS expected process performance
• Reporting near misses, LCز
• Executing recycling or improvement projects to reduce waste of resources (e.g.: energy, compressed air)
• Improving EHS performance through process development/tuning
• Identify, propose EHS improvement and opportunities; contribute to the improvements (e.g.: reduce waste; maximize recycling)
• Action EHS tasks and projects include delivering Safety interactions, risk assessments for all tasks and projects, workplace audits, participating in incident and accident investigations, consistent in continuous application of the SA Golden Rules, and the department lifesaving rules.
• Support internal and external audits.

2.2 Process Control and Optimization:

• Ensure metallurgical and process compliance across all production stages, including furnace operations, casting, homogenization, inspection, and final product validation.
• Leverage advanced process monitoring systems (e.g., MES, SCADA, Fanar) to ensure high-resolution tracking and control of metallurgical parameters throughout the production lifecycle.
• Drive process innovation by developing and deploying optimized casting protocols, furnace treatment methodologies, and homogenization cycles aligned with product specifications and operational efficiency targets.
• Conduct comparative analysis of metal composition data against laboratory standards to validate process integrity and support alloy development initiatives.

2.3 Product Quakity Assurance:

• Execute metallographic evaluations and scheduled quality inspections in accordance with defined protocols.
• Assess trial raw materials from new suppliers through structured metallurgical testing and recommend production feasibility based on performance metrics.
• Perform root cause analysis on customer complaints and internal process deviations using historical data, metallurgical test results, and failure mode diagnostics.
• Support disposition and corrective action planning for non-conforming products.
• Engineer and refine process parameters for both new product introductions and legacy product optimization, including:
• Furnace batching, casting, and dimensional inspection.
• Degassing, filtration, and furnace treatment protocols.
• Metallographic procedures and calibration of analytical instrumentation.
• Maintain and update inspection criteria to comply with evolving quality system standards.
• Facilitate internal and external audits (e.g., ISO, customer-specific) by providing technical documentation and process evidence.
• Champion statistical process control (SPC) initiatives to minimize process variability and enhance product consistency.

2.4 Technical Support

• Resolve complex production challenges involving multi-variable constraints such as operator efficiency, equipment performance, and process throughput.
• Present data-driven technical solutions and recommendations to management for process improvement and strategic decision-making.
• Ensure strict adherence to Standard Operating Procedures (SOPs) and quality system documentation.
• Contribute to the development of management review materials, including technical reports and performance summaries.
• Collaborate with production teams to troubleshoot and resolve casting-related anomalies.
• Prepare and submit monthly technical reports detailing:
• Production yields and recovery rates.
• Process deviations, corrective actions, cost-saving initiatives, and key performance indicators (KPIs).
• Deliver targeted training programs for supervisors, technicians, and operators covering:
• Metallurgical principles, inspection techniques, safety protocols, documentation standards, and analytical procedures.
• Conduct specialized training for Casthouse operators on defect identification and casting process troubleshooting.
• Provide cross-functional metallurgical and quality system training as required.
• Assist in developing the project scope of work and oversee its execution and final handover.
• Lead the team in identifying the root cause of any customer complaint or concern

2.5 Continuous Improvement

• Enhance data acquisition and reporting systems to reduce manual errors and improve traceability.
• Identify and implement corrective and preventive actions to strengthen the quality management system and elevate product quality.
• Evaluate new product inquiries for technical feasibility and recommend process modifications to meet customer requirements and market demands.
• Take the lead and actively contribute to departmental improvement initiatives, ensuring successful implementation of project changes and achievement of desired outcomes.

REQUIREMENTS

Essential qualifications and experience:

• Bachelor’s degree in metallurgical engineering, Materials Science, or related field with minimum 5 years of relevant experience in a Casthouse or aluminum production environment. Preferred: Master’s degree in metallurgical engineering
• Experience with DC casting, alloying, and downstream product requirements
• Good knowledge on computer applications, with integrity and written/spoken communication ability in English
• Good level of leadership and teamwork skills.
• Strong knowledge of aluminum metallurgy and casting processes.
• Familiarity with spectrometry, metallography, and mechanical testing.
• Diagnosing technical problems (product and process related) and causes recommend and implement corrective actions.
• Proficiency in data analysis tools (e.g. Excel, Minitab).
• Practical problem-solving and root cause analysis (e.g., 5-Why, Fishbone).
• Effective communication and teamwork skills.
• Structured levels of managerial expertise