Senior Technician - Process Control

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry.  EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

JOB PURPOSE:

To support recycling casthouse operations by conducting process monitoring, product inspection, metallurgical and chemical analysis, and laboratory testing to ensure product quality and compliance with specifications. The role covers process auditing, metallurgical evaluation, spectrometry, and reporting, ensuring both raw materials and finished products meet required standards.

Ensure products are produced in best quality, on time as per agreed customer requirements and meeting following international standards:

1. ISO 9001: 2015
2. ISO/TS 16949: 2009
3. ISO 14001:2015
4. ISO 45001:2018
5. ISO/IEC 17025

KEY ACCOUNTABILITIES:

EHS & Compliance

•  Follow all EHS procedures, conduct risk assessments, and lead in safety initiatives.
• Maintain 5S housekeeping in laboratory and work areas.
• Ensure compliance with ISO/IEC 17025, ISO 9001, ISO 14001, and OHSAS standards.

Process Monitoring & Control

• Monitor scrap sorting, twin chamber melting, furnace treatment, and VDC casting operations for compliance with procedures, validating parameters and correcting deviations before they impact melt chemistry or product quality.
• Support trial runs and development projects for process optimization.

Product Inspection & Quality Verification

• Conduct billet/T-bar visual inspection, ultrasonic inspection, and billet quality assessments.
• Operate automated billet inspection systems and report defects prior to downstream processing.
•  Coordinate and conduct checks on measuring instruments and inspection equipment.

Metal Quality & Analysis

• Carry out spectrometer-based chemical analysis of liquid metal, scrap, and finished products.
• Calibrate and maintain laboratory instruments to ensure accuracy.
• Interpret test results, prepare reports, and escalate abnormal findings.
• Perform hydrogen measurement, thermal analysis, and metal cleanliness assessments (PoDFA, metallography).
• Prepare samples for macro/microstructure studies, metallography, and mechanical testing.
• Investigate customer complaints through metallurgical analysis and report findings.

Data & Documentation

• Maintain accurate quality records, process KPIs, and laboratory results.
• Support data analysis for continuous improvement.

Continuous Improvement & Support

• Participate in optimization projects, trials, and suggestion schemes.
• Benchmark metallurgical and quality practices against competitors.Provide technical guidance to junior staff in process, metallurgy, and laboratory tasks.

QUALIFICATIONS & SKILLS:

• Accept or reject scrap, finished products based on test and inspection results.
• Quarantine non-conforming material and escalate issues to the management.
• Initiate re-testing or corrective checks when abnormal results are found.
• Maintain and calibrate laboratory and inspection equipment to ensure accuracy.

Minimum Qualifications:

• Technical Diploma in Metallurgy, Materials Science, Chemistry, or equivalent.
• 4–5 years’ experience in aluminium casthouse operations, laboratory, or metallurgy roles.
• Exposure to both casting operations and laboratory analysis (spectrometry, metallography).

Skills:

• Strong knowledge of casting processes, inspection, and metallurgical evaluations.
• Proficiency in laboratory equipment operation (spectrometer, XRF,  metallography equipment).
• Ability to interpret metallurgical and chemical test results and recommend corrective actions.
• Technical reporting, analytical skills, and problem-solving ability.
• Strong teamwork and communication skills.
• Computer literacy (MS Office, data entry, SPC tools)