High strength Nickel alloys are widely used in aerospace applications to make critical components due to their excellent thermomechanical properties. The processing of manufacturing Ni ingots is an energy intensive process which starts with melting and subsequent thermomechanical processing. A typical Nickel alloy is melted 2 to 3 times (VIM/VAR/ESR), and the thermomechanical processing typically involves multiple press and radial forging reductions, reheats in furnaces, and heat treatments to achieve the required grain size and mechanical properties for aerospace and petrochemical applications. Even under controlled conditions, variation in the final product can occur including surface cracks, hidden porosity, undesired grain size, etc. leading to rework and or reprocessing. We will layout and discuss an ICME-based approach to improve the process yield, tracing the billet through its journey from melting to thermomechanical processing while utilizing continuum-modeling and thermodynamics-based models. We will elaborate on the results, challenges, and potential future steps.