Role Summary
This is a senior, plant-based role responsible for running and managing the entire plant laboratory, including building and leading a team of chemists/technicians and ensuring accurate, reliable, and timely chemical analysis to support production, process control, and quality assurance.
Mandatory: The candidate must have prior experience as a chemist in a ferro alloys plant only. Experience from any other industry is not acceptable.
Key Responsibilities
A. Lab Management & Team Leadership
- Act as overall in-charge of the plant laboratory, reporting to Quality Head / Plant Head.
- Build, train, and supervise a team of chemists and lab technicians; prepare duty rosters for round-the-clock operations where required.
- Establish, implement, and continuously improve SOPs for sampling, testing, recording, reporting, and retention of samples for raw materials, process samples, and finished products.
- Set clear turnaround times (TAT) for critical tests and ensure timely delivery of results to production and quality teams.
- Ensure discipline, confidentiality of results, and strong housekeeping (5S) inside the lab.
- Drive a culture of safety and compliance within the laboratory (PPE usage, safe handling practices, incident reporting).
B. Chemical Testing & Quality Control
- Oversee and, where necessary, perform chemical analysis of:
- Raw materials: manganese ores (various grades), coke, coal, quartz, fluxes, and other inputs used in ferro alloy production.
- Process / intermediate samples: tap samples, slag samples, and other in-process samples as per plant control plans.
- Finished products: ferro alloys such as SiMn / FeMn / FeSi / FeCr (as applicable), as per customer and internal specifications.
- Ensure tests are conducted using standardised methods (wet chemistry and instrumental methods such as spectrometric analysis, carbonsulphur analysis, and other relevant techniques), as applicable to the plant.
- Ensure accuracy, repeatability, traceability, and proper sample identification at every stage (from sampling to reporting).
- Maintain instrument calibration routines and logs; ensure working standards and reference materials are used appropriately.
- Monitor and enforce test frequency and sampling plans aligned with production schedules, dispatch plans, and quality requirements.
C. Coordination with Production & Quality
- Coordinate closely with Production to ensure tap/process samples are collected correctly, tested on time, and results are communicated immediately for operational decisions.
- Provide timely feedback to production for process control actions (e.g., adjustments in charge mix, basicity, tapping control, and general furnace/process parameters), based on lab outcomes.
- Support quality improvement initiatives through trend analysis, control charts, and data-driven suggestions.
- Ensure finished product chemistry meets customer and specification requirements; support investigations and corrective actions for off-spec material.
- Assist in customer complaint investigations by analysing retain samples, reviewing records, and preparing technical summaries.
D. Lab Systems, Documentation & Compliance
- Maintain complete and accurate records of all tests, calibrations, reference standards, and lab activities in both physical registers and digital formats.
- Develop and maintain standard test methods, internal quality controls, and checks such as duplicate samples, control samples, and inter-lab verification where relevant.
- Prepare periodic reports for management: daily/weekly/monthly lab performance, quality trends, non-conformities, and action status.
- Support compliance with relevant standards and certifications (e.g., ISO 9001 / ISO 14001 / ISO 45001 or other applicable quality/environment/safety systems).
- Ensure data integrity, proper approvals, and audit readiness for internal/external assessments.
E. Lab Maintenance & Safety
- Oversee maintenance, upkeep, and performance of lab equipment and instruments; coordinate AMC, service visits, and repairs with vendors.
- Ensure availability, proper storage, and controlled usage of reagents, consumables, glassware, reference standards, and lab spares.
- Implement and monitor lab safety protocols: chemical handling, labelling, segregation, safe storage, waste disposal, and emergency response procedures.
- Conduct/supervise safety training and refreshers for lab staff and ensure compliance with PPE and safety guidelines at all times.
- Maintain MSDS/SDS availability and ensure safe disposal practices for chemical waste and broken glassware.
Required Experience(Non-Negotiable)
Experience (Mandatory)
- 5–8+ years of laboratory/quality control experience specifically in a ferro alloys plant.
- Candidates must have worked only in the ferro alloys industry (SiMn/FeMn/FeSi/FeCr). Experience from other sectors (steel, cement, mining, chemicals, etc.) will not be considered for this role.
Education
- B.Sc / M.Sc in Chemistry (preferred) or related science fields.
- Additional qualifications in quality systems, analytical techniques, or safety are an advantage.
Domain Knowledge (Must-have)
- Strong understanding of ferro alloys chemistry, raw materials behaviour, quality parameters, and process control requirements.
- Hands-on exposure to industrial lab equipment and analytical methods commonly used in ferro alloys plants.
- Working knowledge of sampling practices for ores, coke/coal, process samples, slag, and finished alloy samples.
Skills & Competencies
- Strong analytical skills and attention to detail; commitment to accuracy, reliability, and traceability of lab results.
- Experience in leading a lab team and managing shift-based operations where required.
- Familiarity with MS Excel and basic lab/quality software; ability to prepare clear reports and trend summaries.
- Strong coordination and communication skills to work effectively with production, quality, dispatch, and plant management.
- Working knowledge of lab safety, chemical handling, and housekeeping standards.
- Ability to troubleshoot analytical issues (instrument drift, repeatability problems, sample preparation errors) and guide the team in corrective actions.
