Manager - Smelter

Responsibilities

*Key Responsibilities of Role

 

Manager - Smelter – Copper

Production Planning and Execution:

• Lead the entire section's (anode and casting, boiler operation, convertor, crane operations, flue gas desulphurisation, primary smelter/ secondary smelter/raw material handling, refractory maintenance, revert crushing, flash smelting furnace and tapping) production across three shifts, ensuring seamless operations and adherence to the production plan.
• Plan and ensure the availability of materials, preventing any production delays or issues across shifts.
• Execute the business plan for the section, aligning production goals with overall organizational objectives.
• Coordinate with shift in-charges and ensure smooth workflow across upstream and downstream processes.

Process Optimization and Continuous Improvement:

• Drive continuous improvement initiatives to enhance production efficiency and reduce waste.
• Analyze process performance metrics and recommend strategies for improving yield and reducing downtime.
• Develop process optimization projects focused on material handling and equipment usage.
• Collaborate with cross-functional teams to implement best practices for smelting operations.

Quality Assurance and Control:

• Ensure compliance with quality standards across all production processes, conducting routine checks and process parameter analysis.
• Monitor lab assays and operational parameters to ensure minimal deviations from quality standards.
• Review feedback from quality control tests to identify areas for improvement.
• Lead the troubleshooting of any quality-related issues to prevent recurring defects.

Equipment Monitoring and Troubleshooting:

• Monitor equipment performance across shifts, ensuring timely identification of issues and preventive maintenance.
• Direct the scheduling of maintenance demand to avoid unplanned downtime, ensuring equipment runs optimally.
• Troubleshoot equipment malfunctions in real-time, collaborating with the maintenance team to resolve issues.
• Ensure preventive maintenance schedules are followed to minimize breakdowns and extend equipment life.

HSE and Regulatory Compliance:

• Ensure compliance with all Health, Safety, and Environmental (HSE) regulations, including proper handling of materials and equipment.
• Lead safety audits and inspections to proactively identify hazards and enforce corrective actions.
• Direct the implementation of safety protocols and Standard Operating Procedures (SOPs) to maintain a safe working environment.
• Promote a culture of safety among the workforce, ensuring adherence to regulatory and safety standards.

Cost Management and Budgeting:

• Plan and manage the budget for the section, ensuring efficient resource allocation and cost-effective production.
• Monitor and approve PR/PO processes to ensure timely procurement of materials and services.
• Drive cost-saving initiatives by optimizing resource use and minimizing waste across production cycles.
• Review and manage invoice processing to ensure proper cost tracking and financial control.

Resource and Workforce Management:

• Allocate manpower efficiently, including on-roll employees and contractual workers, to meet production demands.
• Plan for manpower needs, including manpower planning for shifts and scheduling based on operational requirements.
• Lead workforce training and development initiatives, ensuring employees are well-versed in operational and safety standards.
• Ensure effective coordination between teams across shifts to maintain production consistency.

Reporting and Data Analytics:

• Analyze key production data, including shift reports, material consumption, and equipment performance, to identify trends and areas for improvement.
• Review and submit accurate production reports, ensuring management has up-to-date insights on section performance.
• Use data analytics to track process performance metrics and drive data-based decision-making.
• Ensure all records are maintained in compliance with regulatory and organizational standards.

Digitization and Tech Adoption:

• Utilize SAP and other digital tools to monitor production, material movement, and equipment performance in real-time.
• Lead the adoption of digital technologies to improve operational efficiency and automate routine tasks.
• Ensure the section’s operations are aligned with the latest technological advancements, driving continuous process improvement.
• Promote the use of digital tools for reporting, maintenance tracking, and data analysis.

Key Stakeholders - Internal:

• Smelter Sections
• Maintenance
• QA Team

Key Stakeholders - External:

• Equipment Vendors
• Regulatory Agencies
• External Auditors
• Regulatory Bodies

Qualifications

Education Qualification:

B.E in Metallurgy

Work Experience (Range of years):

Minimum 10 years of experience in the metallurgy industry