Process Technician

POSITION PURPOSE

The Meltshop Process Technician is responsible for monitoring, controlling, analysing, and optimising key steelmaking process parameters throughout the Meltshop production cycle. The incumbent provides hands-on technical support to Electric Arc Furnace (EAF), Ladle Furnace (LF), Continuous Casting Machine (CCM), billet production, and associated processes to ensure stable, safe, efficient, and repeatable production performance.

The role supports process stability, productivity, yield improvement, energy and consumable efficiency, defect prevention, root cause analysis, and continuous improvement while ensuring compliance with approved operating practices, metallurgical requirements, SHERQ standards, and production targets.

KEY RESPONSIBILITIES

Process Monitoring and Control

Monitor, record, and analyse operating parameters throughout:

• Electric Arc Furnace (EAF)
• Ladle Furnace (LF)
• Continuous Casting Machine (CCM)
• Billet production
• Ladle preparation and turnaround
• Tundish preparation and casting readiness
• Alloy and deoxidant additions
• Flux and slag-forming additions
• Raw material and scrap charging

Identify deviations from approved process windows and escalate or initiate corrective action within delegated authority.

Process Optimisation

Support optimisation of:

• Tap-to-tap time and furnace cycle performance
• Electrical energy and oxygen consumption
• Electrode and refractory consumption
• Metallic yield and recovery
• Ladle treatment and refining time
• Casting speed and sequence stability
• Billet surface and internal process-related quality
• Temperature control from furnace to caster
• Process material and alloy consumption

Recommend practical adjustments to improve stability, efficiency, yield, and throughput.

Process Data Collection and Analysis

Collect, validate, trend, and analyse process data including:

• Heat and cycle times
• Energy and oxygen consumption
• Temperature measurements
• Alloy, flux, carbon, and consumable additions
• Casting speed, superheat, and sequence information
• Yield, recovery, downtime, and process loss data

Ensure process data is complete, accurate, traceable, and available for production review.

Technical and Metallurgical Support

Coordinate with Production, Quality, and Laboratory teams regarding:

• Chemical composition and heat aim requirements
• Temperature and superheat control
• Slag practice and refining performance
• Metallurgical process behaviour
• Process-related billet defects and abnormalities
• Laboratory and production test results

Interpret process and metallurgical information to support timely operational decisions.

Process Verification

Verify adherence to approved:

• Heat recipes and operating practices
• Alloy and material addition practices
• Chemical composition targets
• Temperature windows and tapping practices
• Casting parameters and operating sequences
• Product and customer process requirements
• Production instructions and standard operating procedures

Escalate abnormal conditions and recurring process deviations immediately.

Process Deviation and Problem Solving

• Identify process deviations and abnormal trends.
• Support containment of process-related production problems.
• Record and report significant process deviations.
• Lead or participate in root cause investigations.
• Support corrective and preventive actions (CAPA).
• Verify the effectiveness and sustainability of implemented process improvements.

Documentation and Process Records

Maintain accurate records of:

• Heat numbers and production sequence data
• Process parameters and set-points
• Process monitoring and analysis reports
• Shift and process checklists
• Technical trials and improvement actions
• Production and downtime records
• Process deviation and corrective action reports

Ensure accurate process history and traceability for analysis and continuous improvement.

Instrumentation and Measurement Support

Assist with verification and effective use of:

• Process monitoring instruments
• Temperature measurement equipment
• Weighing and dosing systems
• Process sensors and operator interfaces
• Calibration and verification records

Report defective, unreliable, or out-of-calibration process equipment immediately.

Communication and Operational Support

Work closely with:

• Meltshop Manager and Production Superintendent
• Quality and Metallurgical teams
• Meltshop Shift Foremen
• Furnace and Ladle Furnace Operators
• Continuous Casting Operators
• Laboratory Technicians
• Electrical and Mechanical Maintenance
• SHERQ Department

Communicate process deviations, technical findings, and recommended actions promptly.

Safety, Health, Environment, Risk and Quality (SHERQ)

• Comply with the Occupational Health and Safety Act (OHSA) and applicable company requirements.
• Follow all company safety procedures, permits, and safe operating practices.
• Wear prescribed Personal Protective Equipment (PPE).
• Report hazards, incidents, unsafe conditions, process risks, and near misses.
• Participate in safety meetings, risk assessments, and emergency drills.
• Support ISO 9001, ISO 14001, and ISO 45001 management systems.
• Promote safe, controlled, environmentally responsible, and quality-focused Meltshop operations.

Operational and Technical Reporting

Prepare and maintain:

• Daily process performance reports
• Process deviation and abnormality reports
• Production parameter trends and summaries
• Heat, cycle, energy, yield, and consumable analyses
• Technical trial and process change records
• Corrective action and improvement reports

Ensure accurate, timely, and meaningful technical reporting to Production Management.

Continuous Improvement

• Participate in process optimisation and cost-reduction projects.
• Conduct process capability, trend, and performance studies.
• Support yield improvement, cycle-time reduction, and defect-prevention initiatives.
• Participate in structured root cause analysis and problem solving.
• Promote standardisation and a continuous improvement culture.
• Support production trials, commissioning activities, and implementation of approved process improvements.

Any other duties which may be reasonably required due to the operational requirements of the business.

QUALIFICATIONS

Minimum Requirements

• Grade 12 (Matric) with Mathematics and Physical Science or an equivalent technical qualification.
• National Diploma in Metallurgy, Chemical Engineering, Process Engineering, Mechanical Engineering, or a related technical discipline.

Preferred Qualifications

• BSc degree in Metallurgy / Chemical Engineering.

Advantageous Qualifications

• Steelmaking or metallurgical process training.
• Process Control or Production Technology certification.
• Statistical Process Control (SPC) or process data analysis training.
• Root Cause Analysis / Problem Solving training.
• Occupational Health and Safety Training.
• First Aid Certificate.
• Valid Code B Driver's Licence.

EXPERIENCE

Minimum Requirements

• Minimum 3 years' experience in process control, production, metallurgy, or technical operations within a heavy industrial or manufacturing environment.

Preferred Experience

• Steel manufacturing or primary metals production.
• Electric Arc Furnace, Ladle Furnace, Induction Furnace and Basic oxygen Furnace operations.
• Continuous Casting processes and billet production.
• Process metallurgy and steel chemistry control.
• Industrial process monitoring, trending, and optimisation.
• Production troubleshooting and continuous improvement.

KNOWLEDGE REQUIREMENTS

The incumbent should possess knowledge of:

• Steelmaking processes and Meltshop production flow.
• Metallurgical principles and steel chemistry.
• Process control principles and operating parameter management.
• EAF, LF, and CCM operating practices.
• Process instrumentation, measurement, and data collection.
• Energy, yield, consumable, and productivity drivers.
• Process traceability and production records.
• Statistical Process Control (SPC), trend analysis, and root cause analysis.
• Occupational Health and Safety Act (OHSA).
• ISO 9001 Quality Management Systems.
• ISO 14001 Environmental Management Systems.
• ISO 45001 Occupational Health and Safety Management Systems.

SKILLS AND COMPETENCIES

Technical Skills

• Process monitoring and parameter control.
• Steelmaking process troubleshooting.
• Process optimisation and technical verification.
• Industrial instrumentation and measurement interpretation.
• Technical report writing and presentation.
• Data analysis, trending, and performance interpretation.
• Computer literacy (MS Office, ERP, process control/HMI and production systems).
• Root cause analysis and structured problem solving.
• Process documentation and change control.
• Continuous improvement methodologies.

Behavioural Competencies

• Attention to detail.
• Analytical and systems thinking.
• Integrity and safety awareness.
• Accountability and ownership.
• Clear technical communication.
• Cross-functional teamwork.
• Problem-solving and initiative.
• Time and priority management.
• Sound operational decision-making.

Results and improvement focus.

Pay: R15 000,00 - R22 000,00 per month

Application Question(s):

• Please confirm that you are willing to accept the offered salary

Work Location: In person