Senior Technician

JOB PURPOSE:

To perform tasks associated with sorting of scrap, 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 awareness in the remelt cast house 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
• Takes responsibility for the implementation of mobile equipment safety precautions and rules.

Day to Day Activities

• Performs activities in his shift in a safe and efficient way of accomplishing the production targets. A Senior Technician in the Remelt Cast House shall be capable to step into any of the activities in the remelt cast house. These tasks are:
• Leading the scrap sorting activities
• Melting of scrap, preparing holding furnaces and casting of products
• Finishing of products from homogenization to quality inspection, sawing and packing
• Ensures all sorting and casting units operate consistently and achieve the set targets in a timely, safe and most efficientmanner
• Conveys timely messages to the Seniour Superintendent to prevent any disruption to 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.
• 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

• Ensures all the activities related to sorting, casting and finishing to accomplish 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
• Points out any observed maintenance needs
• Points out any observed improvement possibilities to further improve safety or efficiency.
• Maintains focus on, and involves the shift supervisors and crew in, achieving desired product recoveries
• Ensures any observations to improve the safety performance or efficiency improvements get analysed in a timely manner and corrective measures are implemented as fast and throw as possible.

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:

• High School or 3 years in grade of Senior Technician at EGA
• Completion of training modules specified for Senior Technicians
• Completion of other promotion criteria courses
• English

Minimum Experience:

Minimum 3 years of service as a Senior Technician and passed the relevant training programmes at EGA or in equivalent operational area

Skills:

• Forklift driving licence
• Grab crane driving licence
• Shuffle loader driving license
• Overhead crane driving license
• Highest Safety awareness and leading by example
• Good analytical skills
• Interpersonal communication skills
• Team player
• 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