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Process Engineering and Maintenance Manager (Arab, AL)

United States, Arab Alabama

Cobalt & Specialty Materials

Process & Product Development, Maintenance, Engineering

External Job Description

Umicore is a global materials technology and recycling company currently employing over 10,000 employees, with industrial operations on all continents and serving a global customer base. We focus on application areas where our expertise in materials science, chemistry and metallurgy makes a real difference. Our activities are centered on three business areas: Catalysis, Energy & Surface Technologies, and Recycling, and each business area is divided into market-focused business units offering materials and solutions that are at the cutting edge of new technological developments and essential to everyday life. To learn more, visit us at

To add to our valuable team of dedicated employees, Umicore is currently seeking a Process Engineering and Maintenance Manager at our Arab, AL facility.

Purpose of the Job


This position is responsible for managing USCA Process Engineering and Maintenance department, including being the driving force for the implementation of USCA Capex projects and leading USCA continuous technological improvement.

The Process Engineering and Maintenance Manager role includes:

  • Managing USCA process engineering team to ensure processes performance is analysed, all process documentation is complete, and process improvement are continuously investigated.
  • Managing USCA engineering team on Capex projects, including USCA Master Plan. This plan, which is expected to take 5 years, will centre on the upgrade of USCA leaching and crystallization production units, both from a process and infrastructure point of view.
  • Managing a multidisciplinary technician team tasked with minimizing production disruptions and extending the life of the process equipment through preventative maintenance.

Main Responsibilities

Management of USCA Process Engineering

  • Collaborate with USCA Operations Manager in running efficient, safe, and environmentally sound production processes:
    • Ensure the process engineering team generates production statistical / analytical data for USCA processes, conduct analysis on safety, quality, lead time, costs, and environment related aspects, and develop process improvements
    • Ensure the process engineering team provides technical assistance to the production and lab team when needed
    • Ensure the process engineering team updates process documentation (flowsheet, P&ID, PHA/PRA, SCE/SCP, Work Instructions, Training, etc), per the site Management of Change procedure
  • Collaborate with the CSM team to evaluate strategic business opportunities for USCA:
    • Ensure the process engineering team assesses the technical feasibility of business opportunities:
      • Work with CSM worldwide commercial department in identifying business opportunities,
      • Work with USCA EHS Manager to ensure all safety and environmental aspects are evaluated and all needed permits can be obtained,
      • Work with USCA lab team and Umicore Group R&D to conduct product development research,
      • Work with CSM Global Process & Technology team to set up pilot tests for qualification of processes and technologies
    • Participate in establishing the corresponding business plans
    • Ensure the implementation of the selected business development projects

Management of USCA Capex Projects

  • Monitor USCA Capex budget and planning:
    • Assist the Plant Manager in budgeting USCA Capex projects and establishing priorities
    • Manage USCA monthly reporting on status of projects and comparison between budget and actuals, internal resource allocation, lessons learnt, …
  • Coordinate the development and execution of all USCA Capex projects. Support direct reports by giving guidance and technological input when needed. Ensure that all project deliverables are compliant with legislation.
  • Manage assigned CAPEX projects from feasibility to implementation:
    • Prepare CAPEX request in Sharepoint
    • Work with engineering companies on process and building design (material balance, process flowsheet, P&ID, equipment material and size, instrumentation and PLC type, pipe rack drawings, electrical drawings, building dimensions, etc)
    • Ensure that the process and building design are compliant with US regulations (OSHA standards, ADEM permits, NFPA codes, etc)
    • Establish the Process Hazard Assessment and actively participate in the Process Risk Assessment
    • Issue requests for quotations
    • Select contractors and ensure they comply with the site requirements (safety, liability, etc)
    • Issue purchase orders, and ensure good receipts / invoices are accurate
    • Coordinate the work within timeframe, budget, and according to USCA quality, safety and environmental standards
    • Establish all necessary documentation (SCE/SCP list, PM schedule, Spare part list, Work Instructions, Training, etc) regarding the new processes
    • Provide training to the Operations team (production, maintenance, lab) on the new processes to ensure a smooth transition of the completed projects

Main Responsibilities Continued


Management of USCA Maintenance

  • Ensure USCA maintenance department is managed efficiently: appropriate preventative maintenance / work order ratio, timely response to USCA Operations and EHS needs, optimal inventory management and sourcing strategies, to guarantee USCA reliability, cost efficiency, and full compliance with federal and state regulations

Compliance with EHS

  • Work in close collaboration with USCA EHS Manager to ensure:
    • USCA process engineering and maintenance activities are done in accordance with the site Safety Manual, US federal and state laws, and Umicore EHS standards
    • USCA process engineering and maintenance activities are following ISO 9001 and 14001 standards
    • The site sustainable development goals are established and reached according to Umicore Corporate policy
  • Take an active role in USCA Process Safety Management (Process Risk Assessments, Management of Change, etc)
  • Take an active role in USCA Risk Awareness Program
  • Ensure USCA contractors and service providers respect USCA housekeeping 5S program

Education & Experience

Minimum Bachelor degree in Chemical Engineering

5+ years of chemical process experience in supervisory role

5+ years of experience in Capital Expenditure project management

Knowledge of Process Risk Assessment HAZOP method is a plus

Knowledge of OSHA, ADEM, and NFPA regulations is a plus

Knowledge of CAD is a plus

Umicore is an Equal Employment Opportunity Employer and does not discriminate on the basis of age, race, religion, color, sex, national origin, marital status, genetic information, sexual orientation, gender identity and expression, disability, veteran status, pregnancy status or other status protected by law..

If you need assistance in applying for this position, please contact Paula Kilgore at or by calling Human Resources at (256) 931-3812.

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