Job Summary

The Cast House Manager is responsible for overseeing all cast house operations related to the production of aluminum billet and/or ingot. This role ensures safe, efficient, and consistent casting operations while meeting quality, cost, and production objectives. The Cast House Manager leads daily operations, manages staff, controls process parameters, and works closely with Engineering, Quality, Maintenance, and Production teams to support downstream extrusion requirements and continuous improvement initiatives.

Key Responsibilities

• Direct and manage all cast house activities, including melting, alloying, casting, homogenization (if applicable), and material handling.
• Ensure production schedules are met while maintaining high standards of safety, quality, and efficiency.
• Monitor and control key process parameters such as melt temperature, chemistry, casting speed, and cooling to ensure billet quality and consistency.
• Promote and enforce a strong safety culture within the cast house.
• Ensure compliance with all safety regulations, environmental requirements, and company policies.
• Lead safety audits, incident investigations, and corrective action implementation.
• Partner closely with Quality and Metallurgical teams to ensure aluminum chemistry, billet structure, and casting integrity meet specification and customer requirements.
• Support investigations into quality issues, scrap, and nonconforming material, including root cause analysis and corrective actions.
• Ensure proper documentation and control of casting procedures, specifications, and quality records.
• Lead, coach, and develop cast house supervisors, technicians, and operators.
• Establish clear expectations, performance goals, and accountability for the cast house team.
• Support training and qualification of personnel on equipment, processes, and safety practices.
• Identify opportunities to improve yield, reduce scrap, optimize energy usage, and control casting costs.
• Lead continuous improvement initiatives using Lean, Six Sigma, or structured problem‑solving methodologies.
• Support capital projects, equipment upgrades, and process improvements within the cast house.
• All other duties as assigned.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, Metallurgical Engineering, or a related field required.
• 7–10 years of experience in aluminum manufacturing, casting operations, or melt shop environments.
• Prior leadership or management experience in a production setting is required.
• Experience supporting billet production for aluminum extrusion operations strongly preferred.
• Strong knowledge of aluminum casting processes, alloy chemistry, melt practices, and defect prevention.
• Ability to analyze production, quality, and cost data to drive performance improvements.
• Familiarity with environmental controls, energy management, and safety systems in heavy manufacturing.
• Proven people‑leadership and team‑development skills.
• Strong problem‑solving and decision‑making abilities.
• Effective communication skills across all levels of the organization.
• Results‑driven with a continuous improvement mindset.

Physical & Work Environment Requirements

• Ability to work in a high‑temperature industrial environment.
• Regular presence on the production floor.
• Flexibility to support off‑shift operations or respond to production issues as needed.

Work Environment:

Duties are performed both indoors and in the plant which is an uncontrolled environment subject to extreme temperatures and loud noise.