General Manager Process / Production

Purpose of the Job

• Responsible for the management of the Process operations and Perform duties supporting various Sections of Process RMH, Crusher, Raw Mill, Coal mill, VSK & Rotary Kiln and Cement & Packing Mills.

Key Responsibilities

Plant Operations

• Enable Daily production planning in line with targets and execution plans.
• Analyse plant equipment status and plan for predictive maintenance schedules in coordination with maintenance teams to improve equipment reliability and performance.
• Review process parameters and correct deviations through analysis and solutioning, for example, installation of buffer plate in order to manage pressure parameters.
• Supervise corrective and preventive solutions such as regular changing of refractory and brick line to avoid frequent failure.
• Guide on corrective action in case deviation from process parameters and supervise execution of corrective actions, for example, why-why analysis in case of unplanned downtime.
• Carry out review and analysis of daily process log sheet and other key production parameters and other process indicators such as brick condition, raw mill fan, baghouse fan rpm, grinding media condition etc.
• Proactively drive process/system improvement initiatives such as modification and changes in processes to improve production and cost metrics, for example, introduction of latest technology to optimize cost metrics.
• Carry out regular interactions with internal stakeholders such as maintenance teams, quality, RMH, civil, safety etc.; Interact occasionally with external stakeholders such as vendors, contractors, OEM etc

Process Excellence

• Identify process/system improvement initiatives to optimize overall operational costs & processes.
• Carry out overall cost, inventory & manpower optimization.
• Develops and drive process excellence initiatives such as six sigma interventions, total productivity maintenance etc. to enable superior cost efficiencies and quality levels across the organization.
• Optimization of plant performance with respect to output rate and production.
• Adherence to norms regarding power utilisation, quality, production & emission norms.
• Smooth execution of internal & external projects, material & manpower management, plant supervision & resolution of safety related issues & conflicts.
• Maximization of uptime of major plant equipment (i.e. kiln, mill etc).

Employee Engagement & Safety

• Ensure nil lost time accidents through robust implementation of safety guidelines.
• Drive a culture promoting focus on environment, health and safety across the organization.
• Strengthen employee engagement levels in operations team building a positive working climate for all team members.

Education

B.E / B. Tech from Tier 1 / Tier 2 College with 18+ years of experience.

Experience

• Typical role requires an experience of ~ 18 - 22 years in handling process section at a Cement or related plant.
• Role requires understanding of cement making value chain, knowledge of plant operation, optimization, knowledge of shutdown activities & project commissioning works in addition to technical knowledge of process.
• Knowledge of Process Excellence Tools such as Six Sigma, TPM etc.

Personality & Culture Fit

• Collaborative
• Empathetic
• Extroversion
• Curious
• Integrity
• Creative
• Attention to Detail
• Sound Judgement

Competencies:

Behavioral Competencies

• People Management
• Influencing Skills
• Strategic Thinking
• Change Management
• Problem Solving
• Stakeholder Management
• Decision Making
• Process Orientation

Technical Competencies

• Product Knowledge
• Production Management Techniques
• Project Management
• Quality Management Systems
• Six Sigma, TPM etc
• Safety and Sustainability Protocols