1.              JOB PURPOSE:

Leads the provision of subject matter expertise and delivers value through;

• the setting and control of critical parameters concerned with cell process control in multiple technologies potlines at JA and/or, large size high amperage potlines of AT.
• monitoring and analyzing the key performance indicators and key cost drivers of the different reduction potlines at either Jebel Ali and/or Al-Taweelah to maximize operational performance and efficiency.
• identifying, designing, and implementing process improvement projects to reduce cost and improve quality and customer service to maintain EGA’s competitive edge in the aluminum industry.
• and collaborating with Pot rooms Management and with the relevant support departments to ensure smooth and efficient operation of potlines in terms of metal output, metal purity, energy consumption and environmental emissions and to ensure a continuous improvement to contribute to the achievement of operational excellence and productivity.

2.              KEY ACCOUNTABILITIES:

Strategic Contribution

• Ensures effective cascading of the functional strategy into department business plans to ensure vertical alignment and horizontal integration with other interfacing departmental strategies.

Team Supervision

• Sets the team objectives to comply with the department’s targets and objectives.
• Plans, organises, and supervises the work of the assigned team to ensure that all work within a specific area of the activity is carried out in an efficient manner, which is consistent with operating procedures and policy.
• Provides on-the-job training and constructive feedback to assigned team to support their overall development.
• Promotes the organization’s values and ethics in all activities within the team to support the establishment of a value drive culture within the organization.
• Leads the training and development and effective knowledge transfer to the team to meet the pre-determined standards of competence in jobs skills, knowledge of the job and safe working practices.
• Ensures performance management of the team is managed effectively by ensuring timely reviews and actions as required.

 Budgeting and Financial Planning

• Develops, monitors, and works with the pot rooms management team on the key cost drivers in pot rooms-production, unit energy cost, metal purity and environmental emissions following agreed with targets, budgets, and timescale.
• Provides all the data needed for budgeting and forecasting of potline every month.
• Discusses and convinces the Potline Senior Managers to accept and approve the budget.
• Monitors and identifies the cause of below-target performance indicators and develops effective solutions to remedy them.
• Achieves process Key Performance Indicators (KPI) targets is a critical function of the role with line performance directly correlated with their adherence.
• Monitors departmental activities following agreed targets, budgets, and timescale.
• Investigates opportunities for unit cost reduction through alternate materials for testing and fine-tuning of measurements or methods.
• Ensures all sectional activities are conducted in line with the approved financial guidelines.

Policies, Systems, Processes & Procedures

• Manages and ensures effective implementation of policies, procedures and controls covering all areas of assigned department activity so that all relevant procedural/legislative requirements, fulfilled while delivering a quality, cost-effective service.

Electrolytic Process Management

• Leads/develops process control strategies and standards to sustain and improve process performance and operational efficiencies.
• Establishes production targets and control ranges for the critical process parameters to meet strategic objectives of the smelter
• Anticipates and proactively addresses process KPI deviations given observed deviations in the aluminium reduction processes.
• Ensures development and implementation of adequate process monitoring control systems and quality monitoring systems so that the product meets the agreed specifications and quality deviations are proactively addressed.
• Develops synergy within EGA business units while exploring all business opportunities and implementing changes for effective utilisation of resources to improve product quality and reduce unit cost. Also, encourage sharing best practices.
• Leads the identification of opportunities and leads the execution of improvement projects for Smelter performance improvement, in consultation with concerned area management, to achieve strategic business goals.
• Evaluates plant performance and prepares proposals for equipment and system upgrade/replacement to ensure business continuity and growth.
• Facilitates lean manufacturing initiatives coordinated by the Business Excellence team to achieve effective implementation of Suggestion Scheme, RCM, Kaizen, Six Sigma and 5S.
• Ensures compliance to Quality Management and Environmental Control Systems.
• Establishes general raw material (viz. Alumina, AlF3, Anode supplies, Process Consumables) specifications and contractual specifications related to individual raw material suppliers.
• Initiates actions and coordinates to address quality concerns related to existing suppliers.
• Reviews the raw material quality control strategy for existing raw materials in coordination with concerned areas of operation.
• Reviews and communicates periodic performance evaluation of existing raw materials.
• Develops forecast of raw material quality trends and their implications for the business.
• Liaises with suppliers to positively impact their manufacturing process.

Project Management

• Effectively collaborates with Plant Optimization and Process Improvement on major capital projects such as larger anodes, taller cathode blocks, voltage optimization, etc.
• Monitors and tracks the progress of the projects and ensure that the targets set are delivered.
• Optimizes the process of pot preheating, bath up and early life for their respective technologies in close coordination with Preheat team.
• Develops appropriate information systems in coordination with Industry 4.0 projects such as DBDS, automation, waste control, environmental footprint improvement, etc. to improve business efficiency and productivity.
• Collaborates with internal and external parties to benchmark product quality and production processes and drive initiatives to achieve breakthrough process improvements.
• Initiates and ensures the execution of trials (in-house or in coordination with external parties) and provide business solutions for process improvement.
• Supports Major Projects /Engineering in the successful execution of Brown/Greenfield expansion projects through active participation in FEED, Technical bid evaluation, design/HAZOP reviews, start-up, and commissioning activities.

Management Supervision and Efficiency Improvement

• Keeps abreast of technical developments in operation and process control to initiate and drive process development projects.
• Leads a team of and technicians to work directly with the pot room operations team to achieve the smelters operating objective.
• Directs activities of the technical team to minimize and mitigate any potential disturbance to the potline operation, reduce cost and increase reliability and efficiency.
• Manages internal resources such as process monitoring equipment and tools, consumables to optimize the cost/benefit ratio for effective utilization.
• Facilitates collaboration between site departments and with external resources to benchmark production processes and drive synergy and achieve process & operational efficiency improvements.
• Develops systems to ensure compliance to internal and external audits of Carbon and Port.
• Proposes the acquisition and development of the appropriate IT tools for data analysis.
• Supports the design and development of technical guidelines and all requisite technology documentation for promoting the sales and effective use of in-house developed technologies.
• Ensures that an effective communication and feedback system is in place for prompt resolution of complaints and technical queries.
• Supports the Technology Development team by providing technical advice on design and process changes required for the development of EGA smelting technology.
• Analyses deviations in laboratory analysis and liaise with Laboratory to take corrective actions.
• Supports documentation relating to EGA policies for patents and copyright system.
• Reviews and makes necessary adjustments to the process to accommodate the alumina and other raw material changes required to satisfy the cast house purity demand with minimal process impact.
• Conducts potline sensitivity analysis to the management, for setting the amperage of the potline. Once the decision of amperage creep or de-load is made, all necessary calculations of parameters are done by Jobholder

Business Continuity

• Formulates and executes contingency plans for emergencies such as power interruptions, failure in equipment such as PCS and raw material supply disturbance, etc.
• Provides technical support to the standardisation of contingency plans across EGA sites.
• Sets scenarios to be prepared, tested, and documented with other functional areas. Participates in the weekly drills along with the Operations to enact the various scenarios and fine-tune the response actions.
• Develops and reviews various power shortage scenarios and formulates the way forward in consultation with all stakeholders.

Mentoring, Coaching and Knowledge Transfer

• Provides technical specialist knowledge transfer to contribute to enhancing the technical team’s technical and professional skills.
• Promotes the EGA brand by submitting technical papers and participating in conferences and symposiums.
• Leads the design and development of training modules necessary to meet Reduction Technical training needs.
• Conducts Reduction Technology training for Reduction operation & process control teams to Propagate awareness of the latest technological advancement in the aluminium smelter
• Develops and reviews criteria for proper selection and recruitment of non-supervisory personnel.
• Conducts periodic performance appraisals of supervisory staff and propose changes of status and salary adjustments following company policy.
• Provides coaching and mentoring of national trainees and subordinate staff to make their best contribution to the company.
• Supports participation in business excellence programmes (viz. Suggestion scheme, TPM, AM, RCM, 5S and TAP).

Management Systems Administration

• Establishes Standard Operating Procedures when required, ensuring periodic review of the procedures for safety governance audits as well as to include any additional hazards mitigation introduced through projects.
• Ensures business and quality systems (QA/ EHS/ 5S) are effectively implemented in the department and support recertification against international standards such as ISO.
• Reviews environmental targets in line with smelter objectives to ensure compliance with legal and process requirements.
• Provides technical guidance to reduce, reuse and recycle the waste generated by the smelting process (Waste Management).

Safety, Quality and Environment

• Manages compliance with all relevant safety, quality and environmental management policies, procedures, and control across the section to guarantee employee safety, legislative compliance and are responsible environmental attitude. 
• Plays a vital role in managing emergency situations and minimizing any adverse impact to safety of the people and plant.

Continuous Improvement

• Leads the identification of opportunities for continuous improvement and sustainability of systems, processes and practices considering global standards, productivity improvement and cost reduction.
• Reviews the existing process methodologies and conducts feasibility studies to ensure implementation of continuous process improvements and reduction of the unit cost of production.
• Investigates, analyses, and troubleshoots Pot room technical and engineering issues to de-bottleneck the process and enhance plant productivity.
• Identifies and pursues all opportunities to increase the productivity and efficiency of the pot room operations through reducing the input power and raw materials usage and maximising the metal production output.
• Participates in the research and development projects initiated by EGA in collaboration with universities and technical institutes.
• Interacts with external consultants and organisations in business proposals, productivity and process improvements, security of operation etc.

Reporting

• Ensures that all unit reports are prepared timely and accurately and meet EGA requirements, policies, and quality standards.

3.              Authority/ Decision making:

• Recommends and endorses the pot(s) parameters to enhance productivity, improve energy efficiency and specific material consumptions.
• Provides consultative guidance and reduction technology expertise when requested.
• Prescribes corrective and preventive actions to major process and quality deviations to sustain product quantity and quality and ensure business continuity.
• To review and approve key reports in the online reporting system.
• Participates in recruiting process to ensure selection of high calibre candidates for vacant/new positions.
• Conducts approvals in SAP as per the workflow
• Promotes EGA brand.
• Job holders can advise suppliers on necessary changes to improve the process to meet EGA specifications.
• Manage the team of technicians while fostering a culture of teamwork and job fluidity to ensure efficient resource utilization.
• Leads/supports projects and synergy initiatives which are cross-functional
• To participate in decision-making related to the design and development of new reports.
• To review and get the control strategies and control logics modified through IT to align the reporting/control systems with evolving work practices/processes.
• Provide recommendation and business solutions to ensure effective utilization of Operational budget & CAPEX and control cost drivers.
• To define control limits and exception criteria for major process measures / raw material quality.
• Provides advice and validates changes to raw materials specifications in consultation with Manager Process Control to maintain and improve metal quality.
• Initiate & ensure the execution of trials (inhouse or in coordination with external parties) and provide business solutions for process improvement.
• To review and edit the departmental Standard Operating Procedures periodically to comply with the ISO standards.

• To raise purchase requisitions / approve warehouse stock requests/leave requests.
• To change pot control strategy for adapting to changing process/ raw material characteristics.
• To provide technical recommendations on new and alternate raw materials.
• To design and develop business reports.

Asset Value

Production capacity: Between 150 000 and 578 000 MT of production,

Energy Use: Between 78 and 870 DC MW of energy use

Manning: 8 to 16 (Engineers, Senior Technicians and Technicians)

Challenges:

• A highly diversified business unit that warrants extensive knowledge of technological development for effective recommendations.
• A high throughput (world’s biggest single-site capacity) continuous operation, therefore instant decision making in metal quality and quantity is a prime requirement of the incumbent based on knowledge, experience, procedure, best industry practices & key business drivers.
• With ever-changing and potential variances in the quality of major raw materials, knowledge of its quality and quantity, their source of major input raw materials and variances impacting cost and energy consumed is another challenge for the job holder to track, monitor and make the decision.
• To administer technical team
• To prescribe necessary changes in processes and operational practices to achieve the required results.
• Co-ordinate, advise, persuade, and effectively influence internal and external stakeholders. To achieve business objectives the incumbent raise parameter change requests and implement process changes upon approval.
• During external audits, jobholders can advise on necessary changes to meet and improve the process.
• Conduct approvals in SAP as per the workflow.

To conduct Operational excellence walkabouts with the team and identify opportunities for improvement as well as initiate actions to achieve them.

4.              QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Bachelor’s Degree in Engineering.

Minimum Experience:

• 8 years of experience in similar operations, in process technical or engineering, process control engineering, technical supervisory and management positions in an aluminium smelter.
•  A sound understanding of the aluminium reduction process is mandatory. 

Skills:

• Strategy planning
• Communication and presentation
• Analytical
• Problem-solving
• Mentoring and Coaching Skills
• Interpersonal
• Negotiation
• Planning and organising
• Teamwork
• Leadership
• People management
• Statistical & Process Analysis, 
• Critical Thinking and Problem Solving
• Thorough knowledge of the smelting process.
• Continuous Process Improvement skills
• Project Management
• Software applications