Operator- CCR

Essential Duties and Responsibilities (Key Accountabilities)

• Monitor Plant Operations: Operate and monitor various equipment and systems in the cement plant from the central control room, including crushers, kiln, raw mills and cement mills.
• Process Control: Control and adjust process parameters such as temperature, pressure, flow rates, and material feed rates to ensure smooth and efficient operation of the plant.
• Quality Control: Monitor product quality parameters such as fineness, and composition to ensure compliance with quality standards and specifications.
• Safety Compliance: Adhere to safety protocols and procedures to ensure a safe working environment for all plant personnel. Report any safety hazards or incidents promptly.
• Troubleshooting: Identify and troubleshoot operational issues or equipment malfunctions, taking corrective actions as needed to minimize downtime and maintain production efficiency.
• Shift Handover: Provide detailed shift handover reports to incoming operators, highlighting any ongoing issues, completed tasks, and upcoming activities to ensure continuity of operations.
• Documentation and Reporting: Maintain accurate records of plant operations, equipment performance, process parameters, and production data. Generate daily shift reports for management review.
• Emergency Response: Respond promptly to emergencies such as equipment failures, power outages, or safety incidents. Implement emergency procedures and protocols to ensure the safety of personnel and minimize disruptions to production.
• Collaboration: Collaborate with other departments such as maintenance, quality control, and logistics to coordinate activities, resolve issues, and optimize plant performance.
• Continuous Improvement: Participate in continuous improvement initiatives to optimize plant operations, reduce costs, and enhance productivity. Provide feedback and suggestions for process improvements and efficiency enhancements.
• Training and Development: Stay updated on new technologies, equipment, and procedures relevant to cement manufacturing. Participate in training programs to enhance knowledge and skills related to plant operations and process control.

Additional Duties and Responsibilities

Supervising Refractory and Maintenance Jobs During Shutdown:

Coordinate with maintenance teams to supervise refractory installations, repairs, and other maintenance activities during plant shutdowns.

Ensure that maintenance work is carried out safely, efficiently, and in accordance with established procedures and timelines.

Monitor progress of maintenance tasks, provide guidance to maintenance personnel, and address any issues or challenges that arise.

Working as Acting Shift Engineer in the Absence of Shift Engineer:

Assume the responsibilities of a shift engineer in the absence of the designated personnel.

Oversee overall shift operations, including production, safety, and maintenance activities, to ensure continuity and smooth functioning of the plant.

Make decisions and take appropriate actions to address operational issues, emergencies, and other situations as they arise.

Coordinate with other departments and management to resolve any issues or escalate them as needed.

Knowledge, Skills and/or Abilities (attributes) required.

To perform this job successfully, an individual must be able to perform each duty satisfactorily. The requirements listed below are representative of the knowledge, skills, and abilities required.

Knowledge:

• Cement Manufacturing Processes: Comprehensive understanding of cement manufacturing processes, equipment, and systems, including kilns, mills, crushers
• monitor and adjust process parameters for optimal production efficiency and product quality.
• Safety Regulations and Procedures: Familiarity with safety regulations, protocols, and procedures applicable to cement manufacturing operations to ensure a safe working environment and compliance with regulatory requirements.
• Maintenance Practices: Understanding of maintenance practices and procedures related to refractory installations, repairs, and other maintenance activities during plant shutdowns.
• Emergency Response: Knowledge of emergency response procedures and protocols to effectively respond to equipment failures, safety incidents, and other emergencies during operations.

Skills:

• Operational Skills: Proficiency in operating and controlling various equipment and systems in a cement plant, including the ability to interpret and respond to process data and alarms.
• Problem-Solving Skills: Ability to identify, troubleshoot, and resolve operational issues, equipment malfunctions, and process deviations in a timely and effective manner.
• Communication Skills: Strong communication skills to convey instructions, report information, and coordinate activities with maintenance teams, shift personnel, and management.
• Supervisory Skills: Leadership and supervisory skills to effectively supervise maintenance activities during shutdowns and provide guidance to maintenance personnel.

Abilities:

• Adaptability: Ability to adapt to changing priorities, production demands, and unforeseen circumstances during plant operations and maintenance shutdowns.
• Decision-Making: Sound judgment and decision-making abilities to prioritize tasks, allocate resources, and make critical decisions in high-pressure situations.
• Teamwork: Collaboration skills to work effectively with cross-functional teams, including maintenance, production, quality control, and safety, to achieve common goals.
• Attention to Detail: Keen attention to detail to ensure accuracy in monitoring plant operations, recording data, and supervising maintenance activities during shutdowns.

Key Performance Indicators