Associate Manager

Purpose/Objective

The Shift In-Charge is responsible for overseeing all smelting activities during their assigned shift, including both operational management and safety compliance. This role focuses on maintaining the efficient execution of processes, managing manpower, and ensuring compliance with operational standards. The Shift In-Charge will also be responsible for managing cross-functional coordination with maintenance, production, and safety teams.

Key Responsibilities of Role

Shift In-charge - Smelter – Copper Production Planning and Execution: - Supervise all shift activities across smelting operations (anode and casting, boiler operation, convertor, crane operations, flue gas desulphurisation, primary smelter/ secondary smelter/raw material handling, refractory maintenance, revert crushing, flash smelting furnace and tapping), ensuring production efficiency and adherence to safety standards. - Implement production plans and make real-time adjustments using SAP for tracking and control. - Assess current production scenarios and coordinate next actions with field operators and CROs to ensure smooth operations. - Manage the deployment of contractual manpower, ensuring compliance with both operational and safety standards. - Monitor upstream and downstream sections, making necessary adjustments to meet production targets and maintain workflow continuity. Process Optimization and Continuous Improvement: - Review and optimize refining processes to identify opportunities for cost reduction and productivity improvements. - Implement lean techniques and continuous improvement methodologies (e.g., Six Sigma) to reduce waste and downtime. - Collaborate with engineering, procurement, and quality control teams to resolve operational challenges effectively. - Ensure optimal use and maintenance of refining equipment to prevent breakdowns and extend equipment life. Quality Assurance and Control: - Ensure continuous monitoring and auditing of quality control procedures to maintain high product quality. - Establish critical control points (CCPs) to detect and mitigate deviations in quality during production cycles. - Conduct internal and external quality audits to assess compliance with company standards and regulatory requirements. - Supervise quality control efforts and enforce corrective actions when deviations are identified. Equipment Monitoring and Troubleshooting: - Coordinate closely with the maintenance team to ensure smelter equipment is maintained according to schedule. - Oversee troubleshooting efforts to ensure timely resolution and conduct preventive maintenance to prevent operational bottlenecks. - Take immediate corrective actions in the event of equipment failures, minimizing downtime and production impact. - Schedule regular equipment inspections and enforce maintenance protocols to maintain equipment reliability. HSE and Regulatory Compliance: - Ensure compliance with all safety protocols, including Permit to Work (PTW) authorizations. - Conduct regular inspections to ensure adherence to environmental and safety standards during shift operations. - Promote a culture of safety by ensuring all employees are properly trained on safety protocols and the use of equipment. - Enforce ISO standards and ensure the implementation of 5S for a safe, organized work environment. - Monitor compliance with environmental regulations, minimizing emissions and waste while promoting sustainable smelting practices. Cost Management and Budgeting: - Track and analyze the costs associated with quality control activities, ensuring they remain within the allocated budget. - Efficiently allocate resources for quality assurance, ensuring minimal waste and avoiding overspending. - Implement cost-saving strategies that improve product quality while reducing operational costs, including defects, scrap rates, and material wastage. - Manage invoice processing and PR/PO monitoring to maintain financial discipline across operations Resource and Workforce Management: - Supervise the performance of field operators and contractual manpower, ensuring that tasks align with the production plan. - Monitor CROs' performance, implementing necessary adjustments to optimize production operations. - Foster a safety-conscious environment, conducting safety training and regular evaluations of team members. - Delegate tasks effectively to ensure workforce efficiency and production targets are met across shifts. Reporting and Data Analytics: - Prepare detailed shift-end reports, documenting production progress, equipment performance, safety incidents, and operational challenges. - Coordinate with the incoming Shift In-Charge for seamless transition and follow-up on ongoing activities. - Use data analytics to identify trends, forecast potential issues, and optimize production performance. - Track and analyze key performance indicators (KPIs) to drive data-driven decision-making and continuous improvement. Digitization and Tech Adoption: - Leverage digital tools and automation to streamline workflows and improve operational efficiency. - Implement digital solutions such as SAP to optimize production, material management, and maintenance tracking. - Stay updated on technological advancements in smelting processes and propose the adoption of new tools to improve efficiency. - Ensure alignment with the organization’s digitization initiatives to drive operational excellence. Key Stakeholders - Internal: - Smelter Sections - Maintenance - QA Team Key Stakeholders - External: - Equipment Vendors - Regulatory Agencies - External Auditors - Regulatory Bodies

Technical Competencies

Business Acumen-Copper,Data Analysis and Reporting-NR,Equipment and Operating Systems Know-How-Copper,HSE Compliance and Regulations-Copper,Inventory Management-NR,Metal Accounting-Copper,Production Process Know-How-Copper,Quality Assurance Management and Testing-NR,Resource Planning Management & Scheduling-NR,Smelter Troubleshooting and Solutioning-Copper,Smelting Process Know How-Copper

Qualifications and Experience

Education Qualification: B.E in Metallurgy DME/BSc with over 10 years of experience. Work Experience (Range of years): Minimum 8 years of experience in the metallurgy industry Certifications: Relevant certifications in shift management or process control would be an advantage.