General Superintendent - Rodding Room

1. JOB PURPOSE:

• Plan and control the various stages of the Anode Rod Assembling process to ensure Potline anode requirements are met in terms of availability, quality and operational suitability.

2. KEY ACCOUNTABILITIES:

1. Environment, Health and Safety (EHS)

• Ensure all necessary Environment, Health & Safety procedures, policies, practices and systems are in place across both Rodding Plant phases in line with Company Policy and are adhered to in order to provide a safe working environment with minimal risk.
• Ensure and demonstrate effective EHS leadership within the department.
• Establish systems for forecasting and controlling environmental emissions and waste generation, and review targets in line with smelter objectives to ensure compliance with legal and process requirements.

2. Customer Focus

• Establish systems to understand customer requirements and ensure documentation through Service Level Agreements is in place, periodically reviewed and monitored through feedback mechanisms.
• Ensure delivery of high-quality products in a sustainable, consistent and cost-effective manner.
• Lead the team in upgrading and improving existing plant setups and processes based on customer requirements and conduct related studies.

3. Policies and Procedures

• Ensure standard operating procedures, manuals and training procedures are in place, effectively communicated and adhered to.
• Formulate and align operational best practices and departmental objectives with EGA vision and strategic goals, addressing both short- and long-term priorities for both Rodding Plants, and ensure effective communication and understanding across the team.
• Support documentation related to EGA policies concerning patents, copyrights and new suggestions as required.
• Ensure effective implementation and compliance with EHS Standards, Management Systems, ISO and OHSAS requirements in line with the EGA framework at Rodding Plants.

4. Production

• Define and control the required inventory levels of rodded anodes across both Rodding Plants to ensure consistent operations while considering financial and risk management perspectives.
• Prepare annual anode rodding production plans aligned with EGA strategic vision, with flexibility to adjust according to operational conditions and contingency plans.
• Ensure cost-effective execution of approved production plans across both Rodding Plants with different anode configurations and conduct periodic reviews to ensure business requirements are met across both Potlines.
• Provide realistic estimates of consumable material requirements needed to produce the required number of rodded anodes to support hot metal production.
• Establish effective production management across both Rodding Plants, ensuring timely preventive maintenance, efficient material utilization and consistent achievement of OEE targets.
• Implement FM Global recommendations to ensure risks and fire protection systems comply with applicable standards and regulations.

5. Quality Management

• Establish and implement appropriate quality control systems within the Rodding Plants to monitor deviations from operating parameters and quality standards and ensure timely corrective and preventive actions for the cost-effective production of quality anodes.
• Keep abreast of technical developments within the area of operation and drive process development initiatives.
• Promote plant and process improvements through evaluation and analysis of plant performance while adhering to effective quality control systems and best practices.

6. Budget and Financial Control

• Establish financial strategies for Rodding Plants in line with plant and departmental strategic objectives to define, monitor and control Budget, Capex and related expenditures without compromising plant operational security.
• Monitor the financial performance of Rodding Plants and ensure budgeted KPI targets are achieved through effective implementation of Balanced Scorecards, Dashboards and Review Meetings.
• Effectively manage implementation of business systems related to lean manufacturing, Kaizen events and active participation in suggestion schemes.
• Synergize operations across both Rodding Plant phases to identify and implement opportunities for cash generation, cash conservation and cost reduction.

7. Training and Development

• Define skills and competency requirements and drive recruitment and personnel development to ensure efficient plant operation within approved FTE and overtime limits.
• Drive effective implementation of Performance Management, Talent Management and Development Planning to enhance employee satisfaction and skills development.
• Promote innovation and creativity and encourage participation in business excellence initiatives such as Suggestion Schemes, RCM, 5S and EHS programs.
• Ensure EGA’s core values are effectively communicated, understood and practiced throughout the department to strengthen organizational culture.

3. AUTHORITY / DECISION MAKING

• Hold full responsibility for anode supply to Potrooms, ensuring delivery of more than 463,000 quality anodes from both Anode Rodding Plants at Al Taweelah.
• Maintain daily interaction with the Direct Manager to discuss operational issues, establish priorities and seek approval on matters related to production scheduling, operational challenges, safety and manpower.
• Conduct duties in accordance with Delegation of Authority, procedures and policies.
• Establish annual Rodding Plant financial strategies to define, monitor and control Budget, Capex and Spare Parts expenditure while maintaining operational security and market competitiveness.
• Define and control healthy inventory levels of anodes to support continuous operation of Reduction Cells with various technologies while balancing financial and risk considerations.
• Direct anode rodding activities across both Rodding Plants to maximize productivity and quality, exceed customer requirements and ensure business continuity while maintaining compliance with regulatory and EHS requirements.
• Exercise final authority on all production-related matters concerning both Rodding Plants at Al Taweelah.
• Ensure effective safe operating procedures and compliance due to the high fire and explosion risks associated with molten metal operations.
• Receive guidance and instructions from the Senior Manager – Rodding Plants as required.
• Conduct duties in accordance with Delegation of Authority, procedures and policies.

4. QUALIFICATIONS & SKILLS

Minimum Qualifications:

• HND obtained from Higher Colleges of Technology (HCT) or a Bachelor’s Degree in a relevant Engineering discipline.

Minimum Experience:

• Completion of a minimum of 6 months’ service in Pay Grade 13.
• Minimum of two “Met Expectations” ratings or one “Exceeded Expectations” rating within the last three years, provided the latest rating was not “Needs Development” or “Unsatisfactory”.

Skills:

• Completion of the following courses:
  • Jebel Ali Operation Middle Management Skills Workshop (pre-requisites: Internal Company First Line Management Skills Workshop Levels I & II or Intensive Management Skills Workshop).
  • Jigsaw @ Work (TR/MSW.18.00).
  • Conducting Effective Interim and End of Year Performance Reviews (TR/MSW.19.00).
  • Factory Finance Simulation (TR.MSC.83.00).
  • Safety Management – OHSAS18001 (TRSFW02).
• Leadership Skills.
• Good Communication and Interpersonal Skills.
• Project Management.

Qualifications:

• Graduate Engineer / Diploma of Associate Engineer.

Experience:

• Graduate Engineer with 5 years of experience in a similar position, or Diploma of Associate Engineer with 10 years of experience in a similar position within a continuous manufacturing environment, preferably in an Aluminium Smelter.