General Superintendent - 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:

Monitor, analyze and control the critical quality Indices and key cost drivers of different units of carbon plant, associated facilities and raw materials to maximize operational performance and efficiency.

Identify, design and implement process improvement projects to reduce cost and improve quality and customer service so as to maintain EGA’s competitive edge in the aluminium industry.

KEY ACCOUNTABILITIES:

Product Quality Assurance and Improvement:

• Develop and review anode quality specifications to meet/exceed customer requirements.
• Design, develop, implement and review quality monitoring systems to ensure that the product quality meets the specifications.
• Analyze and investigate product quality deviations, propose remedial solutions and coordinate solutions implementation.
• Identify, plan and coordinate execution of anode quality improvement projects to meet the evolving business needs.
• Provide active support to the Quality Management System, and other Business Excellence programmes to ensure compliance to certification.
• Take an active role in lean manufacturing initiatives coordinated by the Business Excellence team in order to achieve effective implementation of Suggestion Scheme, TPM, RCM, Kaizen, Autonomous Maintenance, Six Sigma and 5S.

Process Control, Monitoring and Improvement:

• Plan and effectively implement the process control monitoring strategy for the concerned area of operation.
• Outline the critical process parameters responsible for efficient operation and sustained performance including their control ranges. 
• Analyze and interpret the monitored data to anticipate process deviations and plan remedial action.
• Review the existing process methodologies and conduct feasibility studies to ensure implementation of continuous process improvements and unit cost reduction.
• Ensure that parameter changes are executed and evaluate the effectiveness of such changes.
• Conduct trials (in house or in coordination with external parties) and provide business solutions for process improvement.
• Keep abreast of technical developments in concerned area of operation to initiate process development.
• Evaluate equipment performance and prepare proposals for equipment upgrade/replacement to ensure business continuity and growth.

Raw Material Quality:

• Develop, review and implement raw material specifications (Coke, Pitch and Purchased Anodes).
• Conduct technical evaluation for selection and approval of new suppliers through supplier visits, process audits and trials (in house or in coordination with external parties).
• Liaise with operational staff and service departments in planning the procurement and delivery of raw material.
• Conduct periodic performance evaluation of raw materials.
• Plan and effectively implement the raw material quality control monitoring strategy in coordination with concerned operational areas.
• Communicate raw material quality deviations to suppliers through supply chain and coordinate corrective actions.

System Development:

• Design and continually develop the on-line data acquisition, archival and reporting system to provide reliable information to drive business decisions.
• Develop and maintain systems for product traceability (for e.g Anode and Rod Tracking System).
• Select and effectively utilize the appropriate tools for data analysis and reporting.
• Develop technical guidelines and all requisite technology documentation for effective usage and promoting the sales of in-house developed systems as part of EGA smelting technology package.
• Support documentation w.r.t EGA policies for patents and copyright applications.

Customer Care:

• Monitor, analyse and investigate anode problems and deviations, propose solutions and coordinate execution of action plans.
• Liaise within and across business units for effective use of the resources to meet the planned targets and customer satisfaction. 
• Develop and execute the communication plan for complaint handling and customer feedback.
• Provide conclusive feedback for the carbon and potroom related improvement projects.
• Identify opportunities for smelter performance improvement to achieve process excellence.
• Support technology development w.r.t technical advice required on EGA smelting technology.

Budget and Financial Control:

• Provide assistance in preparation and implementation of plans and budget for the department following the company’s objectives.
• Identify opportunities and execute projects for unit cost reduction.
• Ensure compliance and effective utilisation of department’s operating budget.
• Compile and review periodically the business performance through balance score card, dashboards and review meetings.
• Promote a culture of value for money and sound financial practice within the team.
• Prepare and reconcile Production & raw material requirement plans, financial reports and mass balance in line with dept. strategic objectives.

Training and Development:

• Develop and review the technical training modules as and when required.
• Ensure proper selection, recruitment and training of non-supervisory staff in consultation with the Manager of the Department.
• Discharge functional supervisory responsibility for non-supervisory team.
• Conduct periodic performance appraisal of non-supervisory staff and recommend changes of status in accordance with company policy.
• Ensure proper training, safety and development of subordinate staff to make their best contribution to the company.
• Provide active support for evaluation and implementation of suggestions to achieve suggestion scheme targets.

Policies and Procedures:

• Prepare and review standard operating practices, manuals, training procedures and ensure adherence to these.
• Advise w.r.t contingency plans to effectively handle breakdown of vital equipment and shortage of raw materials.

Environment, Health and Safety (EHS):

• Ensure the performance of Fume Treatment Systems are within the set standards and, where deviations are noticed necessary corrective actions are formulated and implemented in coordination with operation area Superintendents.
• Adhere to company’s EHS policies by establishing department EHS objectives in consultation with the manager.
• Forecast environmental emission and waste generation and propose their targets in-line with smelter objectives to ensure compliance to legal and process requirements.

General:

• Participate in developing and reviewing periodically departmental objectives covering all the operational dimensions of the department.
• Support Major Projects /Engineering in successful execution of Brown/Greenfield expansion projects through active participation in FEED, Technical bid evaluation, design/HAZOP reviews, start up and commissioning activities.
• Support the research and development projects initiated by EGA in collaboration with universities and technical institutes to solve complex technical problems, improve existing processes or develop new processes.

QUALIFICATIONS & SKILLS:

Qualifications:

• Minimum of HND from Higher Colleges of Technology (HCT) or bachelor’s degree in relevant field of Engineering or higher.
• Chemical/Metallurgy/Mechanical Engineer would be an advantage.

Experience:

• Minimum ten years of work experience in Aluminium industry preferably in Carbon Plant. 
• Minimum three years of work experience at Pay Grade 13 if promoted within the organization

Skills:

Statistical & Process Analysis, Problem Solving, Planning & Organizing, Continuous Process Improvement skills, Teamwork, Communication & Presentation, Project Management.