Assistant General Manager, Process Engineering

Assistant General Manager, Process Engineering

Job Title/ Position

Assistant General Manager, Process Engineering

Department

Operations & Maintenance (Production)

Job Summary

• To provide technical and operational leadership for the optimisation of cement manufacturing processes, from raw material crushing and preparation through raw milling, pyroprocessing, clinker production, cement grinding and related material-handling operations.
• The role is responsible for improving process stability, plant throughput, product quality, energy efficiency and cost performance while ensuring compliance with approved operating procedures, health and safety requirements, environmental standards and the organisation’s manufacturing objectives.

Key Duties and Responsibilities

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.

Key Requirements

Education and Work Experience

• Bachelor’s degree or its equivalent in a technical discipline.
• Postgraduate/relevant professional qualification will be an added advantage.

• Minimum of fifteen years (15) years relevant work experience.

Skills and Behaviours

• In-depth knowledge of cement production processes
• Strong knowledge of the cement industry (local and international) including the trends, challenges, opportunities, regulations and legislations relating to the cement manufacturing industry.
• Strong knowledge of product quality parameters and quality control
• Good knowledge of cement manufacturing equipment and their functionalities
• Strong people management and leadership skills
• Strong problem solving and analytical skills
• Strong relationship management and communication skills
• Good supervisory, coaching and mentoring skills.
• Ability to manage multiple priorities.
• Ability to pay attention to details