General Superintendent - Rodding Room
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About the Role
JOB PURPOSE: Plan and control the various stages of the Anode Rod Assembling process to ensure Potline anode requirements are met in terms of availability, quality and operational suitability.
Key Skills for This Role
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1. JOB PURPOSE
- Plan and control the various stages of the Anode Rod Assembling process to ensure Potline anode requirements are met in terms of availability, quality and operational suitability.
1. Environment, Health and Safety (EHS)
- Ensure all necessary Environment, Health & Safety procedures, policies, practices and systems are in place across both Rodding Plant phases in line with Company Policy and are adhered to in order to provide a safe working environment with minimal risk.
- Ensure and demonstrate effective EHS leadership within the department.
- Establish systems for forecasting and controlling environmental emissions and waste generation, and review targets in line with smelter objectives to ensure compliance with legal and process requirements.
2. Customer Focus
- Establish systems to understand customer requirements and ensure documentation through Service Level Agreements is in place, periodically reviewed and monitored through feedback mechanisms.
- Ensure delivery of high-quality products in a sustainable, consistent and cost-effective manner.
- Lead the team in upgrading and improving existing plant setups and processes based on customer requirements and conduct related studies.
3. Policies and Procedures
- Ensure standard operating procedures, manuals and training procedures are in place, effectively communicated and adhered to.
- Formulate and align operational best practices and departmental objectives with EGA vision and strategic goals, addressing both short- and long-term priorities for both Rodding Plants, and ensure effective communication and understanding across the team.
- Support documentation related to EGA policies concerning patents, copyrights and new suggestions as required.
- Ensure effective implementation and compliance with EHS Standards, Management Systems, ISO and OHSAS requirements in line with the EGA framework at Rodding Plants.
4. Production
- Define and control the required inventory levels of rodded anodes across both Rodding Plants to ensure consistent operations while considering financial and risk management perspectives.
- Prepare annual anode rodding production plans aligned with EGA strategic vision, with flexibility to adjust according to operational conditions and contingency plans.
- Ensure cost-effective execution of approved production plans across both Rodding Plants with different anode configurations and conduct periodic reviews to ensure business requirements are met across both Potlines.
- Provide realistic estimates of consumable material requirements needed to produce the required number of rodded anodes to support hot metal production.
- Establish effective production management across both Rodding Plants, ensuring timely preventive maintenance, efficient material utilization and consistent achievement of OEE targets.
- Implement FM Global recommendations to ensure risks and fire protection systems comply with applicable standards and regulations.
5. Quality Management
- Establish and implement appropriate quality control systems within the Rodding Plants to monitor deviations from operating parameters and quality standards and ensure timely corrective and preventive actions for the cost-effective production of quality anodes.
- Keep abreast of technical developments within the area of operation and drive process development initiatives.
- Promote plant and process improvements through evaluation and analysis of plant performance while adhering to effective quality control systems and best practices.
6. Budget and Financial Control
- Establish financial strategies for Rodding Plants in line with plant and departmental strategic objectives to define, monitor and control Budget, Capex and related expenditures without compromising plant operational security.
- Monitor the financial performance of Rodding Plants and ensure budgeted KPI targets are achieved through effective implementation of Balanced Scorecards, Dashboards and Review Meetings.
- Effectively manage implementation of business systems related to lean manufacturing, Kaizen events and active participation in suggestion schemes.
- Synergize operations across both Rodding Plant phases to identify and implement opportunities for cash generation, cash conservation and cost reduction.
7. Training and Development
- Define skills and competency requirements and drive recruitment and personnel development to ensure efficient plant operation within approved FTE and overtime limits.
- Drive effective implementation of Performance Management, Talent Management and Development Planning to enhance employee satisfaction and skills development.
- Promote innovation and creativity and encourage participation in business excellence initiatives such as Suggestion Schemes, RCM, 5S and EHS programs.
- Ensure EGA’s core values are effectively communicated, understood and practiced throughout the department to strengthen organizational culture.
3. AUTHORITY And DECISION MAKING
- Hold full responsibility for anode supply to Potrooms, ensuring delivery of more than 463,000 quality anodes from both Anode Rodding Plants at Al Taweelah.
- Maintain daily interaction with the Direct Manager to discuss operational issues, establish priorities and seek approval on matters related to production scheduling, operational challenges, safety and manpower.
- Conduct duties in accordance with Delegation of Authority, procedures and policies.
- Establish annual Rodding Plant financial strategies to define, monitor and control Budget, Capex and Spare Parts expenditure while maintaining operational security and market competitiveness.
- Define and control healthy inventory levels of anodes to support continuous operation of Reduction Cells with various technologies while balancing financial and risk considerations.
- Direct anode rodding activities across both Rodding Plants to maximize productivity and quality, exceed customer requirements and ensure business continuity while maintaining compliance with regulatory and EHS requirements.
- Exercise final authority on all production-related matters concerning both Rodding Plants at Al Taweelah.
- Ensure effective safe operating procedures and compliance due to the high fire and explosion risks associated with molten metal operations.
- Receive guidance and instructions from the Senior Manager – Rodding Plants as required.
- Conduct duties in accordance with Delegation of Authority, procedures and policies.
Minimum Qualifications
- HND obtained from Higher Colleges of Technology (HCT) or a Bachelor’s Degree in a relevant Engineering discipline.
Minimum Experience
- Completion of a minimum of 6 months’ service in Pay Grade 13.
- Minimum of two “Met Expectations” ratings or one “Exceeded Expectations” rating within the last three years, provided the latest rating was not “Needs Development” or “Unsatisfactory”.
Skills
- Completion of the following courses:
- + Jebel Ali Operation Middle Management Skills Workshop (pre-requisites: Internal Company First Line Management Skills Workshop Levels I & II or Intensive Management Skills Workshop).
- + Jigsaw @ Work (TR/MSW.18.00).
- + Conducting Effective Interim and End of Year Performance Reviews (TR/MSW.19.00).
- + Factory Finance Simulation (TR.MSC.83.00).
- + Safety Management – OHSAS18001 (TRSFW02).
- Leadership Skills.
- Good Communication and Interpersonal Skills.
- Project Management.
Qualifications
- Graduate Engineer / Diploma of Associate Engineer.
Experience
- Graduate Engineer with 5 years of experience in a similar position, or Diploma of Associate Engineer with 10 years of experience in a similar position within a continuous manufacturing environment, preferably in an Aluminium Smelter.
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