Alcoa

Engineering Manager – Process Safety

Alcoa

full-time

Posted on:

Location Type: Hybrid

Location: Pittsburgh • Pennsylvania • United States

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About the role

  • Step into a pivotal leadership role within our Asset Management team, that will shape the future of safety across Alcoa’s worldwide operations.
  • As Engineering Manager - Process Safety, you will lead the implementation of best practices, governance and continuous improvement across this strategic domain.
  • Working as part of a global organisation with operations in mining, refining, and smelting across multiple continents, you will oversee systems that control high-risk scenarios and play a critical role in safeguarding lives and protecting the environment.
  • Leading and coordinating Process Safety and Functional Safety objectives across all Alcoa refineries, mines, and smelters, ensuring alignment in diverse, multicultural environments.
  • Providing technical authority and governance for regulations, engineering standards, and best practices related to Process Safety Critical Systems and Functional Safety systems globally.
  • Developing and implementing global standards for process safety and functional safety, including leading Safety Integrity Level (SIL) assessments and lifecycle management for safety instrumented systems.
  • Facilitating and participating in risk management activities, such as HAZOP, LOPA, hazard identification, and project safety reviews, while managing risk identification through audits and integrity assessments.
  • Collaborating and building strong networks with plant management, technical teams, and external stakeholders, driving strategic plans, investigations, and initiatives to improve asset safety and reliability.
  • Analysing and optimising system performance, oversee equipment strategies, and work with EHS Centres of Excellence to establish and lead Alcoa’s global Process Safety function, including international travel as required.

Requirements

  • Tertiary qualifications in Chemical or Mechanical Engineering with a Functional Safety Systems accreditation (such as Exida or TUV Certification).
  • Extensive background in Process and Functional Safety engineering within complex environments, complemented by proven experience in an engineering leadership capacity.
  • Proven capability in functional safety, including safety instrumented systems, SIL determination, lifecycle management, and facilitation of risk assessments (HAZOP/LOPA).
  • An ability to influence, consult, and lead across global, multi-location teams with a collegial leadership style and excellent communication skills.
  • Strong consulting, analytical, and problem-solving skills, complemented by a systematic and structured approach.
  • Detailed understanding of Process and Functional Safety domains, reliability strategies, and frameworks.
  • Demonstrates a flexible approach to work, including willingness to work flexible hours to engage and connect with global teams and the ability to travel locally and internationally to support site teams and program delivery.
Benefits
  • Attractive remuneration and variable bonus plan.
  • Flexible hybrid working options available.
  • Employee growth and development opportunities.
  • Partner with senior leaders across regions to drive transformation and innovation.
Applicant Tracking System Keywords

Tip: use these terms in your resume and cover letter to boost ATS matches.

Hard Skills & Tools
Process SafetyFunctional SafetySafety Instrumented SystemsSIL DeterminationLifecycle ManagementHAZOPLOPARisk ManagementEngineering StandardsGovernance
Soft Skills
LeadershipCommunicationConsultingAnalytical SkillsProblem-SolvingInfluencingCollaborationFlexibilityNetworkingStructured Approach
Certifications
TUV CertificationExida Certification