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:
Key Stakeholders - External:
Qualifications
Education Qualification:
B.E in Metallurgy
Work Experience (Range of years):
Minimum 10 years of experience in the metallurgy industry