Lead Engineer - Process Control

We are offering a Fixed-term role for 2 years focusing on ensuring that EGA operates to the latest Cell Lining Technology available, approving and qualifying a diverse material supplier base, undertaking reviews through trials, analysis and autopsy's, ensuring suppliers adhere to EGA specifications and selecting suppliers based on most favourable lifecycle cost analysis to enable cost effective production of molten metal of the required quality. Ensuring Lining drawings are updated as required and pot life prediction is under constant review.

KEY ACCOUNTABILITIES:

• Ensure inspection and follow up actions of lining materials.
• Establish alternative sources of lining materials supply with supply chain and final user teams by techno-economic evaluation.
• Support Supply Chain and Pot Repair teams to maintain lining materials.
• Ensure quality of different lining materials by testing in external labs periodically and/or as per need.
• Initiate changes and drafting of all material specifications for lining. Revise and update Cell Lining Material Specifications, drawings and related quality control documents, which are to be reviewed by operations.
• Prepare tender technical evaluation reports for lining materials.
• Evaluate, test and monitor trial lining materials performance. Also arrange and plan trials with Pot Repair and Potroom where required. Ensure reporting final trial summary from supplier profile till material performance recommending proper action.
• Lead autopsies and provide recommendations through reports.
• Review pot life performance and provide operations with advice on how to best optimise pot life and warning signs of potential failure and overall failure patterns.
• Support Cell Lining Production Quality control.
• Provide recommendations to Operations regarding lining materials and practices that support pot life and/or lower energy costs.
• Liaise with organisations that provide collaborative technical support to EGA in regards to lining.
• Liaise and support EGA Technology and Transfer regarding developments and trials in lining materials and practices.
• Lining process control for EGA.
• Establish and monitor and control critical parameters of cathode casting and cell construction related activities/processes as per the approved design, to ensure the required quality of cathode production process is maintained with desirable product.
• General, development and information management for EGA.
• Ensure all EGA's standards, policies and procedures (safety, security, quality, information security and environmental) are adhered to in all activities and carried out by all employees in the department.
• Discharge functional supervisory responsibility for direct reports and procurement/maintenance of monitoring equipment. Conduct periodic performance appraisal of technicians, recommend change of status and salary adjustments in accordance with company policy.
• Prepare quarterly updates for the yearly 5 years plan of pot failure prediction for different pot designs all potlines.
• Ensure materials and packaging that can be easily disposed of in non-lined landfills or via onsite processes are procured by EGA.
• Maintain regular communication with Manager Environment Control and Lining.
• Provide regular information to Potroom, Pot repair, supply teams and management about actual versus prediction pot failure in each cell technology.
• Maintain close contact with Potrooms regarding cathode performance and supply regarding material issues.
• Support Technology Development, Potroom, Process Improvement, Process Control, Pot Repair and Supply teams with material and lining related information, designs, specifications, etc. where required.
• Technical support to Technology Development and Process Optimization for development activities and new designs by revising or developing drawings, material selection or resources where possible.
• Supervise and maintain Potroom back-flush in SAP as well as related activities from BOM, budget, etc.
• Manage team cascading annual objectives from process control Cell Lining, objectives, on different aspects.
• Support the Pot Lining Technical Supervisor/Engineer Pot construction Quality Control Team with latest quality control information, documents and casting parameters.
• Establish SPC culture in department activities where possible and his team.
• Identify and carry out development studies and investigations required for maintaining and improving operation economy and reliability.
• Ensure proper training, safety and development of national trainees and subordinate staff to make their best contribution to the company.
• Ensure all SOPs, manuals, training procedures, drawings and material specifications are updated as required.
• Contingency plan to effectively face breakdown and/or lining material shortage to enable cost effective and smooth operation when required.
• Develop and maintain efficient information system for processing data and train personnel in fully utilizing information and ensure data is effectively used in process decision making.

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

Engineering Degree preferably in Chemical or Metallurgical discipline or equivalent combined theoretical and practical experience.

• Minimum of 10 years experience in the smelting process, preferably in an Aluminium Smelting Industry in a similar capacity in the process control area.
• Sound knowledge of the reduction smelting process.
• Previous experience in cell lining operations and/or technical support.
• Previous experience in a leadership capacity.

Skills:

• Thorough knowledge of smelting process.
• Statistical Analysis.
• Problem Solving.
• Planning and Organising.
• Software Applications.
• People Management.
• Leadership.
• Business awareness and strategic thinking.