Location: Meghalaya
Division: ACL
BE Chemical / B.Tech Chemical or Diploma (Chemical)
15+ Years of Experience in Cement industry
The Process head is responsible for driving efficiency of the plant and increase production in each section. The process head needs to meet the production targets and also reduce cost of production through efficiency building.
Adherence to all applicable Safety Compliances to ensure Zero Harm to Man, Materials and Machines.
0 accident policy to be adhered to
100% adherence to company’s policies SOP’s and practices. To be completely aligned with company’s value system, ethics and people practices
To perform individually in the capacity of HOD and work cohesively as a team member in ensuring the achievement of the Annual Operating Plan (AOP).
Adaptation of new technology/processes for cost optimization of department/plant in order to rationalize cost of operation
Create processes, SOPs, BCP’s to ensure efficiency and efficacy in the department and continuously reduce cost of operation
Should have the knowledge of Ball Mills and other details like Grinding Media
Management/ Production efficiencies/ reducing cost of Energy etc
Identifying specific cost of The POC/ PCC
Maintain OEE and reliability factor as per targets.
Perform daily walk by inspections on equipment & generate feedback reports
Active safety leader responsible for all process equipment & controls.
Making budgets and ensuring cost efficiency and reduction as per the budget
Understanding of working of pre heater & cooler
Sound knowledge of kiln operation
Coordinate plant activities with other departmental managers.
Review operational plan with direct reports, communicate with management team and coordinate activities such as outage schedules and equipment run time.
Responsible for quality, type and volume of product produced to meet operational plan demands.
Managing kiln and cooler refractory replacement to optimize equipment run time and efficiency within budget.
Direct, review and verify accuracy of production reporting and technical reports.
Participate as a key member of the plant management team; report to the plant manager
Responsible for the development of the production budget and managing to that budget
Direct and manage resources and activities in the area of process improvement,
Oversee annual evaluations and development plans for all production area staff
Ensure optimization of specific heat, power and capacity utilization and 110% of all equipments.
Utilization of AFR to reduce fuel cost.
Analyzing gaps, leakages, pilferage, damages in section and equipment and create plan and execution to remove the same.
Monitoring and training on complete CCR operation.
Ensuring productivity to meet dispatch targets.
Experience / Knowledge of cyclone jamming removal / snowman and kiln coating removal with adequate safety measures
Maintain all statutory compliances as applicable.
Complete maintenance scheduled to be made and executed of preventive, predictive and conditioned based monitoring.
Maintenance of records as per safety guidelines or maintenance schedule.
To implement best preventive maintenance (PM) practices under SAP Module.
Ensuring availability of spares, consumables, parts etc as per budget and online on SAP
Ensuring complete data requirements, analysis and MIS as required is maintained on time and on SAP
Manpower planning, manpower training and attrition control within team to be done.
Developing 2nd Line Leadership and Succession Planning
Ensuring training calendar for all M, S, W grades are followed and aligned with training and development policy
To report any unfair and unethical or unsafe practices immediately to higher concern.
To ensure best housekeeping activities, waste/scrap disposal on time.
Implementing 5S systems in department and CFT.
Drive TQM and TPM to get future ready for six sigma and kaizen culture
Good Team Handling Skills
Target Driven to achieve production requirements of the company
Leadership skills
Planning & Organizing,
Delegation
Must have knowledge of budgeting (CAPEX/Opex).
Analytical & Problem Solving
Data Oriented / Well versed in excel and computer systems
Change Advocacy