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