Shift Incharge Process - Sponge Iron

Role & responsibilities

To lead and manage the shift operations of sponge iron kilns (500 TPD & 200 TPD), ensuring smooth production, optimum efficiency, safety compliance, and quality standards while minimizing downtime and resource wastage.

Monitor and drive the execution of scheduled daily production plan through a team of well-qualified technicians and operators to ensure that the daily production targets are met without compromising plant equipment health and finished goods quality, thus ensuring optimal efficiency, productivity, and profitability

Create shift schedules of various workforce to ensure continuous Sponge Iron production operations within both kilns and submit the same for validation to Manager Process.

Responsibilities

1. Production & Process Control

* Supervise and monitor sponge iron production process in both 500 TPD & 200 TPD kilns.

* Maintain optimum operating parameters (temperature, pressure, feed rate, coal & iron ore ratio, kiln speed, etc.).

* Ensure achievement of daily production targets with minimum process deviation.

* Monitor kiln, cooler, ESP, and other critical equipment during shift.

2. Shift Management

* Lead a team of operators, supervisors, and technicians during the shift.

* Allocate manpower as per requirement and handle shift handover/takeover properly.

* Maintain shift logbook with accurate production & downtime details.

3. Quality Control

* Ensure quality of sponge iron (Fe content, metallization, fines percentage, etc.) as per standards.

* Coordinate with Quality Control (QC) department for testing and corrective actions.

4. Safety & Compliance

* Enforce strict adherence to safety protocols & statutory compliance during operations.

* Conduct regular safety checks and encourage safe work practices among workers.

* Report and address near-miss incidents, unsafe acts, or equipment abnormalities.

5.Maintenance Coordination

* Identify operational issues and coordinate with maintenance teams (mechanical, electrical, instrumentation) for timely rectification.

* Ensure preventive maintenance schedules are followed to avoid unplanned downtime.

6. Reporting & Documentation

* Record shift-wise production, fuel consumption, raw material usage, and process deviations.

* Report equipment performance and highlight bottlenecks to senior management.

* Support in preparing MIS reports for production and energy consumption.

Key Skills & Competencies:

* Strong knowledge of sponge iron manufacturing process (rotary kiln operations).

* Ability to handle 500 TPD & 200 TPD kiln process parameters effectively.

* Leadership & team-handling skills.

* Problem-solving & decision-making ability under pressure.

* Knowledge of DRI process safety and pollution control norms.

Preferred candidate profile

• Strong understanding of SIU plant operations and maintenance, including knowledge of kilns operations, and other related equipment
• Proven track record of successful plant management and operational excellence
• Knowledge of health, safety, & environmental regulations

Strong computer skills, including proficiency in Microsoft Office.