Technician - Process Control

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry.  EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

JOB PURPOSE:

To monitor and control the Cathode Casting Process, Pot Relining Process, Pot Delining ( Taweela only), Pot Cut out, Preheat and Bath up, identify deviations from specified acceptance limits and assists Engineers in monitoring non-routine and development work and in correcting/streamlining operations.

KEY ACCOUNTABILITIES:

Monitoring and Quality Assurance:

• Monitors the Cathode sealing operation through measurement of cast iron temperatures, preheat temperatures and sampling of cast iron.
• Monitors the Cathode construction activities through construction stages by measurement of dimensions, temperatures and pressure and time delays etc.
• Monitors the Pot cut out, delining (Taweelah only), pot preheat and start up activities and report the findings to Snr. Process Engineer and Supervisor, Pot Repair for necessary corrective actions if any.  
• Detect the process anomalies and non-conformances; determine causes for such and assist process engineers/supervisors and production personnel in rectifying / correcting the process.
• Inspects and sample as received raw materials and process materials, record in relevant databases and SAP, etc. and supply samples to laboratory for necessary analysis.
• Assist  Supervisor/ Engineer/ Snr. Process Engineers testing raw materials and reporting ( Jebel Ali Site)   
• Assists Supervisor/ Engineer/ Snr. Process Engineers in the measurement/monitoring work on different projects in various areas.  This needs in-depth knowledge of the process.
• Compilation and distribution of data for different trial using data taker
• Prepares and presents the data in graphical and statistical form (SPC) manually as well as through personal computers.
• Detects the process anomalies and non-conformances, determine causes for such and assists process engineers and production personnel in rectifying/correcting the process. Prepares and maintains the daily, weekly and monthly records/ reports of the monitoring results manually as well as by using personal computers.
• Prepare monthly inventory report based on physical count.
• Fabricates and maintain various measuring equipment and calibrate the instruments. Follows the prescribed monitoring procedures and job safe practices for respective area of work.  Follows the monitoring frequencies, sample size and conduct measurements and to report timely for corrective actions.

Internal Processes:

• Interacts with Supervisor/ Engineer/ Snr. Process Control Engineers, Snr. technician Process information for job planning and feedback purposes.
• Discusses plant condition with area supervisor to ensure that measurements are carried out on normal conditions and to provide feedback on abnormalities (only Taweelah).
• Interacts with Laboratory analysts, for sampling and analysis of various in- process and raw materials.
• Acting in place of senior technician (shift in charge) during his absence in managing shift
• Responsible for data accuracy within the stipulated time
• Assist in maintaining 5 S in their respective areas.

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Science Graduate or a Diploma in chemical or metallurgical discipline from a recognised institute./PEC Technical training programme  or equivalent . 

Minimum Experience:

• Should possess the knowledge of production process and manufacturing stages in a continuous process industry preferably an aluminium smelter. The job holder should have minimum 5 years industrial experience in a similar position and knowledge of statistical principles. For internal candidates , two years in Grade 7 or 4 years in Grade 6 in the same department.

Skills:

• Conversant with spreadsheet and database program of personal computers for analysing the monitored data in various areas. 
• Should be able to extract relevant information from Potrooms satellite and host (supervisor) computer.
• Good knowledge of the RPMS data base, data entry and report generation.