Senior Superintendent - Recycling

JOB PURPOSE:

To organise all production activities associated with scrap sorting, casting and finishing of all Remelt Cast House products in the most efficient and safe manner to maintain the quality of products and in order meet production targets and for the satisfaction of EGA customers.

KEY ACCOUNTABILITIES:

EHS

• Promotes safe and efficient processes and awarness in the remelt casthouse to accomplish Zero Accidents, top quality products and lowest possible production costs
• Takes on responsibility to establish maintains excellent housekeeping and 5S standards
• Supports the EHS Council and makes performance enhancement and continuous improvements to reduce risks to safety and the environment

Day to Day Activities

• Overseas all employees in his shift and leads them with regards of safe and efficient way of accomplishing the production targets.
• Checks the hot metal reports to understand the number of crucibles expected every shift and co-ordinates the transfer through counter parts in Reduction as per production planning requirements
• Maintains effective communication with PS1 or equivalent role to attain metal flow at a desired rate and understand equipment status clearly
• Ensures all sorting and casting units operate consistently and achieve the set targets in a timely manner
• Conveys timely messages to the Hot Metal Coordinators and Scrap Procurement Team to prevent any disruption to hot metal movement
• Ensures in-house and purchased scrap is charged consistently to maintain scrap at minimum levels.
• Advises and assists supervisors in difficult situations like metal leaks to restore control in an organised manner.
• Monitors the online controlling and documenting systems (SCADA, MES, Analytics, EPMS system and SAP) to monitor and achieve KPIs
• Ensures metal distribution to all casting employees

Policies and Standards

• Ensures that Operations and Documentation are closely controlled & monitored according to the Operating, Metallurgical and Safety Procedures documented under ISO 9001/2015, IATF 16949:2016; ISO 14001:2015; ISO 45001 quality, safety and environmental management systems.
• Monitors the online controlling and documenting systems such as SCADA, MES, Analytics, EPMS system and SAP where applicable to observe and achieve KPIs.

Productivity

Directs through technicians all the activities related to casting and finishing to attain and maintain the required production, quality and safety targets

Monitors the scrap sorting and casting figures and cascades relevant information to casthouse management

Co-ordination

• Exchanges information based on current statistics with regard to equipment status to supervisors of cast houses to ensure a smooth flow of metal
• Discusses planned and preventive maintenance schedules of main equipment with supervisors of all areas to enhance flexibility
• Maintains focus on, and involves the shift supervisors and crew in, achieving desired product recoveries

Emergency:

In case of emergency of the below cases the job holder has a shared responsibility with operation and ERT teams to mitigate the risk and perform according to the emergency procedures.  

• Evacuation of Personnel
• Main Gas Failure
• Gas Line Fracture/Failure
• Major Metal Spill
• Power Failure
• Hydrogen Sulphide in Gas Supply
• Loss of Air & Water Supply
• Sea water over tapping and surface water flood
• Shortage of manpower
• Major Rain or Storm Event

Developing Others :

 Motivates a team of multicultural personnel to continuously improve the following:

• Safety
• Training & developing shift personnel
• Casting & finishing rates
• Hot metal movement in the department & proper distribution of metal as per set priorities
• Follow up on qualitative analysis
• Adherence to production schedule to meet customer requirements
• Product recovery rate
• Alloy recovery rate
• Reduction of re-work
• Reduction of rejections
• Reduction off compaction batches
• Scrap recycling rates
• Optimized scrap utilization

AUTHORITY/ DECISION MAKING:

• Managing all direct reports with regards of safety, quality and efficiency as well as ethical behaviour
• Highlights to area management any threat to operations that could affect production, quality of the product and any significant safety issues or personnel matters that require his attention
• Decides on hot metal distribution to casting centres and stops and controls pot tapping based on machine breakdowns in the Recycling Casthouse
• Manage emergencies in a safe manner

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Bachelor’s degree in relevant field of engineering or 5 years in Supervisory grade of EGA operations
• Completion of training modules specified for Shift Co-ordinators
• Completion of other promotion criteria courses

Minimum Experience:

• Minimum 3 years of service as a supervisor including the GT programme at EGA or in equivalent operational area

Skills:

• Highest Safety awareness and leading by example
• Good analytical skills
• Interpersonal communication skills
• Team leader
• In depth knowledge in ISO requirements – safety, quality and environmental standards
• Working knowledge of productivity and total quality management systems
• Ability to solve problems and think creatively