Job Title: Casthouse Manager
Department: Operations
Reports To: Plant Manager
Position Summary
Century Aluminum is seeking a driven and technically skilled Casthouse Manager to lead the safe, efficient, and high-quality operation of the casthouse at our Mt. Holly facility. This position is responsible for overseeing all aspects of molten metal handling and casting operations, with a primary focus on billet production. The Casthouse Manager will lead a team of supervisors and operators, ensuring adherence to production targets, quality standards, safety protocols, and cost objectives.
This is a hands-on leadership role for someone passionate about casting technology, team development, and continuous improvement in a fast-paced, heavy industrial environment.
Key Responsibilities
Operational Oversight
- Direct all daily operations of the casthouse, including billet casting, metal handling, and downstream processes.
- Ensure production meets quality, tonnage, and schedule requirements while minimizing downtime and waste.
- Drive execution of the daily production plan in alignment with plant goals and KPIs.
Safety & Environmental Compliance
- Promote a strong safety culture by ensuring compliance with all safety policies and procedures.
- Lead hazard identification, risk reduction, and root-cause investigations related to safety incidents.
- Ensure environmental compliance and responsible handling of molten aluminum and casting byproducts.
Team Leadership & Development
- Supervise, coach, and develop a team of shift supervisors, operators, and technical staff.
- Set clear expectations and provide ongoing performance feedback.
- Support cross-training and skill development to build a resilient and high-performing team.
Quality & Process Control
- Oversee quality control processes to ensure billets meet internal and customer specifications.
- Partner with Quality and Technical teams to analyze data, identify trends, and address root causes of defects.
- Lead continuous improvement initiatives focused on casting performance, metal recovery, and product consistency.
Maintenance & Equipment Management
- Coordinate with maintenance teams to ensure reliability of casting equipment, molds, and support systems.
- Participate in planning and execution of preventive maintenance and capital improvements.
Cost & Efficiency Management
- Monitor and manage operating costs, including materials, utilities, and labor.
- Identify cost-saving opportunities through process improvements and operational efficiency.
Communication & Reporting
- Provide regular updates to the Plant Manager on production, safety, quality, and staffing.
- Contribute to budget planning, production forecasting, and long-range strategic planning.
Qualifications
Education & Experience
- Bachelor’s degree in Engineering, Metallurgy, Industrial Technology, or related field preferred (or equivalent work experience).
- 5+ years of experience in a casthouse or aluminum casting environment, with at least 2 years in a leadership role.
- Strong background in billet casting, molten metal handling, and downstream operations.
Skills & Attributes
- Proven leadership and team development capabilities.
- Solid knowledge of safety and environmental best practices in a heavy manufacturing setting.
- Strong problem-solving and decision-making skills.
- Experience with process control systems, casting equipment, and lean manufacturing principles.
- Excellent communication and organizational skills.
Working Conditions
- Industrial manufacturing environment with exposure to heat, molten metal, and heavy equipment.
- Required to wear PPE including flame-resistant clothing, safety glasses, gloves, and hearing protection.
- On-site role with availability for off-shift support as needed.