Process Manager, Mfamosing at Lafarge Africa Plc Full Time

Job Title: Process Manager, Mfamosing

Job Identification: 2422
Location: Mfamosing, Cross River
Employment Type: Full-time

Summary of the Job
Run the process department in accordance with the annual and the long-term plan. Participate for the functions he oversees to the advanced management cycle. The missions that have the greatest impact are:

• As part of the management team, promote safety in the plant.
• Improve plant reliability and performance by optimizing the process.
• Implement the process related Best Practices and standards.
• Contribute to the reduction of production costs by optimizing the process.
• Provide the plant with a medium and long term analysis of the prospects and prepare the basics for necessary process/environment related investments.
• Make sure that the production of the raw mix, clinker and cement conforms to quality and production demands.
• Participate and contribute to professional networks in his field.
• Coordinate and develop people reporting to him.

Main Responsibilities
Process:

• He or she is responsible for improving the performance of the plant’s workshops in the short, medium and long term. To do this, he or she must :
• Monitor the process performance of the entire plant on a day to day basis and define corrective actions together with maintenance and production.
• Define process optimisation actions together with quality, production and maintenance; monitor the actions and the results.
• Organize on a daily basis process inspections and review of performance.
• Identify and conduct studies, tests and measurements within the Process department in order to improve performance.
• Define the day to day set points.
• Ensure correctness of sensors.
• Ensure the quality of process data reported.
• Define an audit plan and supervise the audits to detect irregularities and find potential improvements.
• Contribute to fuel cost optimization (optimization of lowest fuel cost) by ensuring (optimizing) process condition which allows a maximum utilization of alternative fuel and raw materials.
• Ensure progress in control loop optimisation and high-level automation.
• Ensure existence and correctness of procedures.
• Ensure that audits and studies are documented and shared.
• Forster the process awareness within all departments in the plant.
• Promote exchanges between the Processes and Production departments.
• Participation in the plant managers’ network.
• Coordinate actions with the Technical Centre/ CIP/MSGN.

Environment:
Depending on the plant organization:

• Define together with the Environmental manager the process conditions which allows the plant to comply current and future with all environmental regulations.
• Ensure together with production that process is operated in a way to minimize emission.

Quarry: Raw Mix Preparation

• He or she is responsible (together with the quarry manager) for the optimisation of the raw mix logic to ensure a raw mix at the desired composition with a minimum of variations.
• Ensure that there is a regular communication between the quarry, process and quality for adjusting the raw mix to the problems of burning.

Plant Management Cycle:

• Promote exchanges between his or her own departments and the other departments in the plant.
• Promote the use of LH information and knowledge tools (product platform, Best Practices, Vade-Mecum, Team workspace, etc.).
• Make the different departments teams aware of the environment aspects.
• Run information meetings and make his or her teams aware of safety matters and check that safety regulations are respected.
• Formulate the vision and set the priorities of the plant with the Production/Operations manager.
• Define the Plant Development Plan (PDP) with the CIP/MSGN contacts support.
• Define investments needs relevant to improved plant performance, CAPEX budgets and ensure execution of related projects.
• Prepare and participate in the plant OH&R review profiling talent management.

Industrial Excellence:

• Ensure that the production commitments in terms of volumes, quality, deadlines, cost and environmental standards are respected.
• Optimise and adapt the production process and equipment in line with the PDP.

Stakeholder Relations:

• Represent the company in front of local authorities and union representatives. Promote company values and image in the local social, economic and environmental communities. Ensure that the laws and regulations pertaining to the activity are respected as well as protection of the environment in compliance with group standards.

People Development:

• Induct new recruits, monitor the development of potentials, and propose training schemes for his or her teams in order to optimize their skills.
• Build and facilitate training courses inside and outside the plant.

Job Dimensions
List of direct / indirect reports:

• Process Engineers, Plant statistician, Process technicians, and Industrial trainees/interns.
•  N.B: Organogram may vary slightly depending on plant circumstances

Budget control:

• Significant influence on variable and fixed costs.

Key interfaces, stakeholders and relationships:

• Production , Quality,H&S, Environment, Quarry,Projects, Maintenance and HR departments:
• Other authorizations given by organization chart and internal regulations.

Context of interfaces:

• The Process Manager leads the optimisation campaign team and works very closely with all plant departments, focuses on optimal technical conditions and advises the works team.
• This ensures the achievement of production targets and continuous improvements on power consumption, fuel usage and clinker factor therefore reducing significantly the production costs and improving environmental performance.
• The responsibility of the Quarry raw mix quality is shared between the Process and Quality manager.
• The process manager role is also key to developing process knowledge and skills across the plant to meet with current and future challenges.
• As a result of this heavy technical content, the process manager has to develop an excellent cross-functional relationship with all departments and is leading, facilitating or contributing in a number of transversal activities in the plant.

Key Performance Indicators (KPIs)

• Having a stable process at lowest possible variable cost.(RC/tcem, RC/GJ,RC/kwh)
• Minimum quantity of “out specification” products during operations.
• Number of stops due to process reasons.
• Application of best practices and use of data bases.
• Respect of procedures and quality objectives in accordance with the commercial and industrial departments.

Profile Required
Level of education / qualifications normally required:

• Degree in Chemical Engineering or in general Engineering with process engineering as the main subject.
• Certified by LafargeHolcim as a SPREAD/PPE engineer.
• Good knowledge of the physico-chemical products, of relevant parameters and standards applicable to cement manufacturing.
• Good knowledge of statistical process control methods and experimental design.
• Good knowledge of project management methods.

Specific Work experience:

• 5 to 7 years’ experience in a process role depending on the size and challenges of the position.

Technical / Functional Skills:

• Level III in process in a complex plant, otherwise level II)
• Level I in quality control.
• Level I in Environment.
• Level I in automation.
• In-depth knowledge of the cement making process.
• General knowledge of physics, chemistry, science of heat and computing.
• Knowledge of the chemical parameters that affect the quality of cement.
• General knowledge of process control tools.
• Knowledge of environmental standards and plant process safety.
• Have an overview of the latest innovations in the cement industry.

Behavioral competence:

• Intellectual curiosity and strategic thinking.
• Innovative and Autonomous
• Analytical skills, Objective focus, Rigor.
• Courage and integrity Intellectual humility, Honesty, Respect.

Leadership and managerial abilities:

• Communication skills, Coaching and teaching ability, listening skills, team spirit.
• Adapting to change and creativity and can work in a cross disciplinary way.
• Ability to run teams and work groups.

Application Closing Date
Not Specified.