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Process Operations and Optimisation
- Coordinate and monitor process operations across crushing, raw material preparation, raw milling, coal milling, kiln and cooler operations, clinker handling and cement grinding.
- Review operating parameters and process trends to identify bottlenecks, instability, production losses and improvement opportunities.
- Lead process optimisation initiatives aimed at improving kiln, mill and production-line performance.
- Establish optimum operating parameters for major plant equipment and ensure adherence by production teams.
- Conduct process audits, heat and material balance studies, efficiency assessments and performance benchmarking.
- Recommend adjustments to operating practices, process controls and equipment configuration to improve plant performance.
- Support the stabilisation and performance testing of new, upgraded or recommissioned plant equipment.
- Analyse production data and initiate corrective actions where performance deviates from approved operating standards.
Production Performance and Capacity Utilisation
- Support the development and implementation of daily, monthly and annual production plans.
- Work with Production and Maintenance teams to maximise equipment availability, utilisation and production-line output.
- Monitor clinker and cement production against approved targets and investigate significant performance gaps.
- Coordinate process interventions required to restore stable operations following breakdowns, shutdowns or process disturbances.
- Provide technical support during plant start-ups, shutdowns and emergency operating conditions.
- Participate in daily production and operational review meetings.
- Ensure process improvement activities are aligned with production requirements, equipment condition and market demand.
Energy and Cost Optimisation
- Monitor and drive improvement in specific heat and electrical energy consumption across the manufacturing process.
- Analyse the major drivers of fuel, power, grinding media, refractory and other process-related costs.
- Support the optimisation of fuel mix, including coal, gas and approved alternative fuels.
- Identify and implement initiatives to reduce process waste, production losses and cost per tonne.
- Collaborate with Finance and relevant operational teams in preparing process-related budgets and monitoring expenditure.
- Evaluate process-improvement proposals and provide technical justification for operational or capital investment.
- Promote the efficient use of raw materials, additives, fuels, power and other manufacturing resources.
Quality Management
• Collaborate with Quality Control and Production teams to maintain stable raw meal, clinker and cement quality.
• Monitor the impact of process parameters on product quality and initiate appropriate corrective action.
• Support raw-mix design, kiln-feed control, clinker quality improvement and cement-grinding optimisation.
• Ensure operating practices support approved product specifications and applicable quality standards.
• Investigate recurring quality deviations and coordinate root-cause analysis and corrective actions.
• Participate in product trials involving new raw materials, additives, fuels or process configurations.
- Ensure process changes are properly evaluated, documented and communicated before implementation.
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