Adani Group—Manager - Smelter

Job description

Description: The position is responsible for leading and overseeing all production activities within their section across three shifts, ensuring smooth operations, material availability, and adherence to the production plan. This role is pivotal in driving process optimization, improving equipment efficiency, and ensuring compliance with quality, safety, and regulatory standards. The Section In-Charge is tasked with managing resources, controlling costs, and implementing digital tools to streamline operations. By fostering a culture of continuous improvement and safety, they ensure alignment with organizational goals, while leveraging data analytics to inform decision-making and enhance operational performance. Requirements: Education Qualification: B.E in Metallurgy Work Experience (Range of years): Minimum 10 years of experience in the metallurgy industry 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