Lead Mechanical Engineer

Job Locations US-AL-Bay Minette
Job Type
Full Time
Bay Minette

Position Overview

Novelis is the world leader in aluminum rolling and recycling, producing an estimated 19 percent of the world's flat-rolled aluminum products. We work alongside our customers to provide innovative solutions to the aerospace, beverage can, automotive and high-end specialty markets.


Headquartered in Atlanta, Georgia, USA, Novelis has approximately 11,600 employees in 33 operating facilities on four continents and is investing $2.5 billion to build a new low-carbon recycling and rolling plant in Bay Minette, Alabama. The highly sophisticated facility will serve growing demand for aluminum beverage can sheet in North America. The new facility will also serve the automotive market, where aluminum is the fastest growing material as automakers make plans to achieve their sustainability goals. It will aim to be net carbon neutral for Scope 1 and 2, be powered primarily by renewable energy, use recycled water and be a zero-waste facility.


The Novelis Bay Minette, AL team is seeking for Lead Mechanical Engineers for Hot Mill (1) and Cold Mill (1) to work on site. The Engineers in those roles will report to the Engineering, Maintenance, Reliability & Automation (EMRA) Leader of the respective area. The ideal candidate will be responsible for leading Mechanical engineering and providing support in this area to contribute to the achievement of the plant’s safety, quality, sustainability and budget objectives. This position will guide and handle the activities of others related to reliability/maintenance, Industry 5.0 and keep current with the constantly evolving technology, balancing it with the needs of the operations to bring forth improvements in automated systems and methods.

Responsibilities & Qualifications


  • Embrace the Novelis Safety Principles to build a zero-injury culture and the Novelis cultural beliefs of Be Open, Build Trust, Say Anything and Be Authentic!
  • Responsible for the plant effort on Safe Work Practices and optimal design for EHS.
  • Responsible for the full scope of the Mechanical engineering project including budget control, schedule, and compliance with safety, environmental and sustainability requirements, to assure performance against expectations.
  • Lead discussions on equipment design, detailed engineering with the Mill OEMs and third parties.
  • Coordinate the mechanical building, commissioning, and acceptance tests of a new World Class Manufacturing Hot or Cold Mill in this facility.
  • Travel locally and abroad to perform inspections, technical meetings, and receive training.
  • Meet assigned project commitment, timelines and work
  • Elaborate scope of project, analysis technical and commercial offer and submit purchase request for approval.
  • Contribute to the operational readiness of the plant production commissioning (elaborate and deliver training, elaborate maintenance plans, FMEA, fine tune the equipment and process for optimal performance).
  • Develop the technical team on hard and soft skills
  • Provide a strong mechanical understanding of process, civil, and Mechanical components involved in their equipment
  • Develop and define the Key Performance Indicators (Uptime, MTTR, MTBF, PM Completion, etc.) for Mechanical reliability. Create, lead and communicate the monthly Mechanical Reliability Dashboard for the facility based on these KPI’s and yearly report to management on all aspects of Mechanical Reliability within the facility.
  • Develop and refine the Mechanical preventive/predictive maintenance program in a systematic, professional manner coordinating all efforts with operations, engineering and the mechanical team, to ensure the program is properly approved and endorsed.
  • Provide administration, control and analysis of all data, records and equipment histories to continually review and refine PM/PdM frequencies.
  • Coordinate and provide appropriate Mechanical training on PM/PdM techniques for selected Mechanical maintenance and engineering personnel on appropriate topics.
  • Coordinate and perform Root Cause Failure Analysis (RCFA) for all mechanical significant failures in the facility.
  • Maintenance of equipment covering all phases of heavy industrial plant engineering, typical of the metals industry
  • Assist in solving, advanced analysis and identify areas of potential advancements in the processes, equipment, and facilities to achieve increased profitability through reduced costs, increased efficiency, improved quality, increase production output and optimized equipment uptime.
  • Perform Failure Mode Effects Analysis (FMEA) and Reliability Centered Maintenance (RCM) as specified by the Reliability Master Plan.
  • Work closely with the Reliability & Engineering and Utility Managers, develop conceptual and functional requirements for short- and long-term process and equipment development (facility planning) consistent with the business plan.
  • Technically lead maintenance technicians and engineers as needed- to resolve and prevent maintenance and engineering problems and to develop training programs on processes and equipment for the maintenance staffs.
  • Develop and maintain relationships with suppliers and other technical resources inside and outside of the Site and Company
  • Assignment to an on-call rotation to provide after-hours and weekend support as required to assist maintenance in the troubleshooting and resolution of issues having an immediate impact on plant performance. This can involve providing direction/mentorship remotely and/or onsite.
  • Support the management of the CAPEX and OPEX budget
  • Repetitive failures are identified, and the PM is refined by dynamic and relevant review of predictive and other inspections, analysis of equipment histories, maintenance cost reports and failure reports, review of service and inspection records and analysis of work order data.
  • Provide engineering expertise to project work and selection of replacement or new equipment to help ensure consistency and standardization of components and ease of maintenance
  • Constantly search for innovations and continuous improvement.
  • Prepare and present robust capital expenditure estimates, schedules and requests, including sound financial analysis/justification, for management approval.
  • Review Site equipment and technology for robustness, reliability and obsolescence. Where needed, develop plans for modifications and/or upgrades.
  • Influence regional and/or global decision-making by preparing and communicating technical information to senior management on matters with significant business impact, such as regional/multi-site capital expenditures or regional process/product improvements

Minimum Qualifications

  • Bachelor's degree in Mechanical Engineering.
  • Minimum 8 years of experience as Mechanical Engineer.
  • Experience supporting the process group and the maintenance group in reliability efforts
  • Willingness to work in a self-managed team environment is necessary
  • Good methodical aptitude for equipment problem-solving and related issues.
  • Result oriented and decision-making capability.
  • Proven leadership skills to advise, lead and develop other personnel to accomplish personal, plant and corporate objectives
  • Excellent communication (oral and written) skills; ability to connect with all levels in the organization
  • Project management skills
  • Experience must include developing scope of work using P&ID's, specifications, and project requirements to specify and complete the mechanical, pneumatic and hydraulic.
  • Prove digital literacy with software applications proficiency, including Microsoft Office, AUTOCAD.
  • Able to travel up to 30 - 50% (North America and Internationally) in the first 3 years. After that period, the travel will be less than 10%.
  • Sponsorship for the United State of America VISA is not offered for this position.

Preferred Qualifications:

  • Steel or Aluminum Rolling process.
  • Previous experience on large capital project
  • Have worked with large pieces of equipment (Gearbox, spindles, Fume Exhaust)
  • Basic understanding of capabilities for controls and servo systems and an understanding of maintenance procedures and principles of equipment reliability.
  • Experienced in trouble shooting mechanical systems including pneumatics, tooling issues, measurement feedback systems, and basic design robustness.

What We Offer:

Novelis' benefits say a lot about how we care for each other. Our employees and their families have many different needs. As a result, our benefits offer choices on many levels and are high in quality, driven in the marketplace, and affordable. These are a few of the benefits we offer to support you and your family’s well-being:

  • Medical, dental and vision insurance
  • Health savings accounts – Company Funded Health Savings Account (HSA) and Health Reimbursement Account (HRA)
  • Company-paid basic life insurance and Additional voluntary life coverage
  • Paid vacation and competitive personal time off
  • 401(k) savings plan with company match
  • Retirement savings plans – medical and prescription drug coverage through private exchange
  • Employee assistance programs – available 24/7 to you and your family
  • Wellness and Work Life Support - career development and educational assistance

At Novelis, we believe our culture of collaboration is what differentiates us, and we would love for you to consider building a career with us. Novelis provides equal employment opportunities to all employees and applicants. All terms and conditions of employment at Novelis including recruiting hiring placement promotion termination layoffs recalls transfers leaves of absence compensation and training are without regard to race color religion age sex national origin disability status genetics protected veteran status sexual orientation gender identity or expression or any other characteristic protected by federal provincial or local laws.

Location Profile

Novelis’ newly announced Bay Minette facility will be located 35 miles northeast of Mobile, AL and 45 miles west of Pensacola, FL and is expected to create approximately 1000 high-paying, advanced careers in modern manufacturing and become fully operational in 2025. This highly sophisticated rolling and recycling facility will be the first of its kind. It will primarily serve our customers in the beverage can and automotive markets. Novelis is committed to the community and will actively build partnerships in Baldwin County focused on recycling, STEM education and workforce development.


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