General Superintendent -Proc. Ctrl. Eng.

Strategic Contribution

• Ensures effective cascading of the functional strategy into department business plans to ensure vertical alignment and horizontal integration with other interfacing departmental strategies.

Team Supervision

• Sets the team objectives to comply with the department’s targets and objectives.
• Plans, organises, and supervises the work of the assigned team to ensure that all work within a specific area of the activity is carried out in an efficient manner, which is consistent with operating procedures and policy.
• Provides on-the-job training and constructive feedback to assigned team to support their overall development.
• Promotes the organization’s values and ethics in all activities within the team to support the establishment of a value drive culture within the organization.
• Leads the training and development and effective knowledge transfer to the team to meet the pre-determined standards of competence in jobs skills, knowledge of the job and safe working practices.
• Ensures performance management of the team is managed effectively by ensuring timely reviews and actions as required.

Budgeting and Financial Planning

• Develops, monitors, and works with the pot rooms management team on the key cost drivers in pot rooms-production, unit energy cost, metal purity and environmental emissions following agreed with targets, budgets, and timescale.
• Provides all the data needed for budgeting and forecasting of potline every month.
• Discusses and convinces the Potline Senior Managers to accept and approve the budget.
• Monitors and identifies the cause of below-target performance indicators and develops effective solutions to remedy them.
• Achieves process Key Performance Indicators (KPI) targets is a critical function of the role with line performance directly correlated with their adherence.
• Monitors departmental activities following agreed targets, budgets, and timescale.
• Investigates opportunities for unit cost reduction through alternate materials for testing and fine-tuning of measurements or methods.
• Ensures all sectional activities are conducted in line with the approved financial guidelines.

Policies, Systems, Processes & Procedures

• Manages and ensures effective implementation of policies, procedures and controls covering all areas of assigned department activity so that all relevant procedural/legislative requirements, fulfilled while delivering a quality, cost-effective service.

Electrolytic Process Management

• Leads/develops process control strategies and standards to sustain and improve process performance and operational efficiencies.
• Establishes production targets and control ranges for the critical process parameters to meet strategic objectives of the smelter
• Anticipates and proactively addresses process KPI deviations given observed deviations in the aluminium reduction processes.
• Ensures development and implementation of adequate process monitoring control systems and quality monitoring systems so that the product meets the agreed specifications and quality deviations are proactively addressed.
• Develops synergy within EGA business units while exploring all business opportunities and implementing changes for effective utilisation of resources to improve product quality and reduce unit cost. Also, encourage sharing best practices.
• Leads the identification of opportunities and leads the execution of improvement projects for Smelter performance improvement, in consultation with concerned area management, to achieve strategic business goals.
• Evaluates plant performance and prepares proposals for equipment and system upgrade/replacement to ensure business continuity and growth.
• Facilitates lean manufacturing initiatives coordinated by the Business Excellence team to achieve effective implementation of Suggestion Scheme, RCM, Kaizen, Six Sigma and 5S.
• Ensures compliance to Quality Management and Environmental Control Systems.
• Establishes general raw material (viz. Alumina, AlF3, Anode supplies, Process Consumables) specifications and contractual specifications related to individual raw material suppliers.
• Initiates actions and coordinates to address quality concerns related to existing suppliers.
• Reviews the raw material quality control strategy for existing raw materials in coordination with concerned areas of operation.
• Reviews and communicates periodic performance evaluation of existing raw materials.
• Develops forecast of raw material quality trends and their implications for the business.
• Liaises with suppliers to positively impact their manufacturing process.

Project Management

• Effectively collaborates with Plant Optimization and Process Improvement on major capital projects such as larger anodes, taller cathode blocks, voltage optimization, etc.
• Monitors and tracks the progress of the projects and ensure that the targets set are delivered.
• Optimizes the process of pot preheating, bath up and early life for their respective technologies in close coordination with Preheat team.
• Develops appropriate information systems in coordination with Industry 4.0 projects such as DBDS, automation, waste control, environmental footprint improvement, etc. to improve business efficiency and productivity.
• Collaborates with internal and external parties to benchmark product quality and production processes and drive initiatives to achieve breakthrough process improvements.
• Initiates and ensures the execution of trials (in-house or in coordination with external parties) and provide business solutions for process improvement.
• Supports Major Projects /Engineering in the successful execution of Brown/Greenfield expansion projects through active participation in FEED, Technical bid evaluation, design/HAZOP reviews, start-up, and commissioning activities.

Desired Candidate Profile

• Minimum Qualifications:

  • Bachelor’s Degree in Engineering.

  Minimum Experience:

  • 8 years of experience in similar operations, in process technical or engineering, process control engineering, technical supervisory and management positions in an aluminium smelter.
  • A sound understanding of the aluminium reduction process is mandatory.

  Skills:

  • Strategy planning
  • Communication and presentation
  • Analytical
  • Problem-solving
  • Mentoring and Coaching Skills
  • Interpersonal
  • Negotiation
  • Planning and organising
  • Teamwork
  • Leadership
  • People management
  • Statistical & Process Analysis,
  • Critical Thinking and Problem Solving
  • Thorough knowledge of the smelting process.
  • Continuous Process Improvement skills
  • Project Management
  • Software applications