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Lead Engineer - Smelting Development Projects
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Lead Engineer - Smelting Development Projects - Pay Grade H
1. JOB PURPOSE:
Provides technical expertise and insights; plans, leads and guides a team of engineers to identify, lead and update mid to long term technical reduction development strategy and improvement across both sites JA and AT, focusing on operational excellence whilst focusing on the below key deliverables in line with defined strategies.
Provides technical expertise and insights; plans, leads and guides a team of engineers to identify, lead and update mid to long term technical reduction development strategy and improvement across both sites JA and AT, focusing on operational excellence whilst focusing on the below key deliverables in line with defined strategies.
- Execute project opportunities with stakeholders and support the reduction debottlenecking activities.
- Provide technical support to the smelter management regarding the resolution of critical issues affecting metal production and identify improvements that will contribute to overall smelter performance.
- Translate business problems into justified growth initiatives to enhance and/or, maintain EGA’s competitive edge.
- Lead governance to ensure effectiveness of change management and sustainability.
- The setting and control of critical parameters concerned with cell process control in prototype cells/section and projects at JA and/or AT site.
- Monitoring and analyzing the key performance indicators and key cost drivers of the prototype cells at either JA and/or AT site.
- Collaborate with reduction operation and other relevant support departments to ensure smooth and efficient operation of prototype cells/sections and projects.
- Build business performance management systems to measure progress and performance of deployed solutions and projects.
- Lead and facilitate the best practices across the reduction.
- Challenge existing practises, escalate critical matters and develop countermeasures for mid and long-term issues.
- Ensure continuous process improvement philosophy and maintain the company’s’ competitive edge in the aluminium industry.
- Leads, and guides the management and monitoring of the latest technology prototype cells development as well as all technology related trials conducted in various cells in the potlines at both EGA sites and externally.
- Adopt and promote of industry 4.0 and drive the scope of Smelter of the Future.
- Supports Technology Transfer in preparation of technology packages, process and operational readiness.
- Work with Major Projects/Engineering in executing Brown/Greenfield expansion projects through participation in FEED, Technical bid evaluation, design/HAZOP reviews, start-up and commissioning activities.
2. KEY ACCOUNTABILITIES:
Strategic Contribution
- Develops and reviews medium and long-term production plan in alignment with strategic goals.
- Ensures effective cascading of the functional strategy into department business plans to ensure vertical alignment and horizontal integration with other interfacing departmental strategies.
- Leads and conducts progress reporting of the strategy execution in line to targeted timelines.
- Develops and promotes decision support system for Reduction to support operational efficiency.
Environment, Health & Safety
- Ensures compliance with all relevant safety, health and environmental management policies, procedures, and controls.
- Ensures employee safety, legislative compliance and a responsible environmental attitude and standard within legal limits.
- Develops and deploys monitoring systems to ensure adherence to company’s EHS policies.
- Identifies the requirements from stakeholders on the key issues and potential improvements/opportunities.
- Provides technical expertise and support to reduce, reuse and recycle the waste generated by the smelting process (Waste Management).
Product Quality Assurance and Improvement
- Ensures governance of development and implementation of adequate quality monitoring systems so that the product meets the agreed specifications and quality deviations are proactively addressed.
- Ensures developed projects, sensors and tools is serving the purpose to meet the stakeholders’ expectations to enhance the process.
- Leads the effective synergising 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 and ensures timely analysis and testing for regular maintenance of solutions over time.
- Leads the identification of opportunities and manages the execution of improvement projects for Smelter performance improvement, in consultation with concerned area management, to achieve strategic business goals.
- Leads and identifies the mechanism to capture value of products developed and align with the stakeholders on the concept.
- Ensures compliance to Quality Management Systems.
- Facilitates lean manufacturing initiatives coordinated by the Business Excellence team to achieve effective implementation of Suggestion Scheme, TPM, RCM, Kaizen, Autonomous Maintenance, Six Sigma and 5S.
- Ensures that advanced statistical and other analytical tools are used to provide actionable insights, identify trends, and measure performance.
- Promote EGA brand by submitting technical papers and participating in conferences and symposiums.
- Ensure legal and security of developments by registering via IPs and patents where applicable.
Operational Performance and Efficiency Improvement
- Defines productivity improvement roadmap and set milestones to achieve the goal.
- Manages collaboration between both EGA sites and with external resources to benchmark production processes, drive synergy, and achieve process & operational efficiency improvements.
- Ensures and manages latest Machine learning models are deployed to enhance the process.
- Leads synergising within EGA business units while exploring all business opportunities process control strategies and standards to sustain and improve process performance and operational efficiencies.
- Leads/develop process control strategies and standards to sustain and improve process performance and operational efficiencies.
- Establish production targets and control range for the critical process parameters to meet strategic objectives of the smelter.
- Leads process and operational readiness of different new technologies internally and/or externally.
- Anticipates and proactively addresses process KPI deviations of prototype cells/section and projects.
- Manages the execution of trials (in house or in coordination with external parties) and manages business solutions for process improvement.
- Interacts with direct reports and peers in management/stakeholders and vendors to share information and improve cross departmental processes.
- Leads the effective collaboration with internal and external parties to benchmark product quality and production processes and drive initiatives to achieve breakthrough process improvements.
- Keeps alongside of technical developments in area of operation to initiate and drive process development projects.
- Manages appropriate information systems in coordination with internal/external developers to improve business efficiency and productivity.
- Proposes the acquisition and development of the appropriate IT tools for data analysis.
- Ensures documentation of in house developed solutions.
Budgeting and Financial Planning
- Plan and manage activities in accordance with agreed targets, budgets and timescale.
- Develops, monitors, and works with reduction development manager and operational manager on the key cost drivers of prototype cells 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 prototype cells/section every month.
- Manage the Cash flow of OPEX and CAPEX for programs driven by the department.
- Ensure reporting of cash flow forecast & effective utilisation of the OPEX and CAPEX.
- Explore and uncover opportunities for unit cost reduction through appropriate cost-benefit analysis.
- Conducts periodic review of the business performance KPI’s through Balance Score Card, Dashboards and Review Meetings.
People Management
- Manages the effective achievement of assigned objectives through the leadership of the section by setting of individual objectives, managing performance, developing, and motivating staff to maximise sectional performance.
- Leads the talent development initiatives for the assigned department, collaborating with technical/discipline experts and thereby ensure the availability of talent to fit business requirements.
- Acts as a role model and drive adherence to organizational values and ethics by employees of the assigned department to foster a value driven culture within the organization.
- Nurtures the culture of innovation and creativity and encourages participation in business excellence programmes.
- Promotes a positive work environment and ensure growth is encouraged while integrity is developed and protected.
- Leads and supports the development of National Trainees and Graduate Trainees to develop capabilities as per the business and operational strategies.
- Provides coaching and mentoring of national trainees and subordinate staff to make their best contribution to the company.
- Supports active participation in business excellence programmes (via Tamayaz, Suggestion scheme, TPM, AM, RCM, 5S and TAP).
- Ensures best practices are shared amongst the reduction.
Policies, Systems, Processes & Procedures
- Manages and ensures effective implementation of department policies, procedures and controls covering all areas of assigned department activity so that all relevant procedural/legislative requirements are fulfilled while delivering a quality, cost-effective service.
Innovation and Continuous Improvement
- Leads the identification of continuous improvement opportunities and conducts workshops to drive adoption of process changes through effective collaboration and expectation setting.
- Explores the implementation of new ideas and capturing the value in the smelter and execute initiatives to achieve breakthrough process & efficiency improvements.
- Introduces plant automation and AI initiatives, and big data solutions.
- Works with external/internal consultants to establish the scope of Smelter of the Future and any improvement project.
- Identifies the next generation of process measurement tools focusing on product quality and safety.
- Reviews the product quality for sustainability and adhere to EHS requirements.
- Manages periodic performance evaluation of existing product and projects to stakeholders.
- Leads the identification of opportunities for continuous improvement and sustainability of systems, processes and practices considering global standards, productivity improvement and cost reduction.
- Responsible for the knowledge management of the section.
- Provides technical expertise to support Major Projects/Engineering in successful execution of Brown/Greenfield expansion projects through active participation in FEED, Technical bid evaluation, design/HAZOP reviews, start up and commissioning activities.
- Proposes and supports the research and development projects initiated by EGA in collaboration with universities and technical institutes.
- Interacts with external consultants and organisations in business proposals, productivity and process improvements, security of operation etc.
Customer Experience Management
- Leads the development of standardised systems for delivery of high-quality products/projects across both EGA sites.
- Ensures that an effective communication and feedback system is in place for prompt resolution of complaints and technical queries.
- Provides specialist support to Technology Development R&D team by providing technical advice on design and process changes required for development of EGA smelting technology internally and externally.
- Provides technical input and supports the strategy for establishing EGA as a supplier of world class Reduction Process Technology.
- Identifies and ensures the execution of opportunities for smelter performance improvement to achieve process excellence.
Sustainability & Audit
- Ensures adherence to standard operating practices, manuals, and training procedures.
- Evaluates plant performance based on operational efficiency, reliability, and quality metrics.
- Recommends preventive action where appropriate, focusing on process adherence and data integrity.
- Guides and supports documentation relating to EGA policies for patents and copyright system.
- Supports Technology Development team by providing technical advice on design and process changes required for development of EGA smelting technology.
- Manages documentation of planned and systematic activities during product development.
Stakeholder Management
- Leads the development and maintenance of effective key business relationships with all relevant external/internal entities and all sections with the highest standards of business ethics.
Reporting
- Ensures that all unit reports are prepared timely and accurately and meet EGA requirements, policies, and quality standards.
3. AUTHORITY / DECISION MAKING:
- Participates in recruiting process to ensure selection of high calibre candidates for vacant/new positions.
- Recommends and endorses change to process parameters to improve processes and product quality.
- Advises on selection and design of new equipment to improve operational efficiency.
- Conducts approvals in SAP as per the workflow.
- Prescribes corrective and preventive actions to major process and quality deviations.
- Leads/supports cross functional and cross-divisional projects and synergy initiatives.
- Promotes EGA brand.
- Provides consultative guidance and reduction expertise.
- Manages the team of engineers and technicians.
- Provides recommendations/business solutions to ensure effective utilisation of Operational budget and CAPEX.
Dimensions:
- Area of impact: EGA smelter division (JA + AT)
- Production capacity: >2.7 million Ton (JA + AT)
4. QUALIFICATIONS & SKILLS:
Minimum Qualifications
- Bachelor’s Degree, preferably in Metallurgical or Chemical or Electrical or Mechanical discipline.
Minimum Experience
- 8 years’ experience in the smelting process with 3 years’ experience with growing managerial accountability in roles within similar operations, preferably in an aluminium smelting industry.
Skills
- Strategic thinking and business awareness skills
- Advance data analytics tools and software knowledge
- In depth knowledge of the aluminium industry
- Working knowledge of pot room is preferable
- Ability to be a change-agent
- Leadership and teamwork
- Communication, presentation and interpersonal skills
- Critical thinking and problem solving
- Decision-making, planning and organising
- Continuous improvement and quality focus
- Coaching, mentoring and project management skills
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