Kiln Coach at HBM Nigeria Plc (Formerly Lafarge)

About the Job

• The kiln Coach is responsible for guaranteeing efficiency and optimization of the burning line by working with the process, quality and maintenance teams, and to improve plant performance by developing the Control Room Operators to mastery level of competency in VRM and kiln operations.
• This is achieved through daily performance monitoring, evaluation and feedback, maintaining and improving the plant efficiency through analysis of specific process parameters and ensuring conformity with Safety, Environmental and Quality guidelines.

What you'll be doing

• Perform all tasks in a safe and efficient manner.
• Analyze all process incidents and work with CCRO to mitigate the impact of such incidents and propose solutions to prevent future reoccurrence.
• Monitor application of Production SOP’s.
• Coordinate the development of operational procedures (SOPs) for the execution of all production related tasks in the plant.
• Support Plant operators to achieve operational consistencies by:
• Leading incident review analysis process with CCR operators
• Setting operational objectives from the operator incident review log data analysis
• Reviewing and analyzing the shift production charts and report.
• Identifying the possible cause of process target deviations and gaps in optimum conditions.
• Reviewing and analyzing the clinker quality control data
• Reviewing and analyzing the raw mix preparation quality control data
• Reviewing and analyzing shift downtime reports from the software (ADAP, etc)
• Monitor and ensure compliance with environmental regulations.
• Supports plant operators training and development by:
• Identifying the training and development needs for CCR operators and patrollers
• Conducting effective one –on-one training activities
• Making effective use of available training media for training delivery (CECIL + Produce & Maintain)
• Developing an effective structured on the job training program (OJT)
• Conducting effective group training activities.
• Design and develop training modules.
• Leading role in POM implementation
• Participate in the incident analysis process and contribute to improvement recommendations.
• Ensure alignment of SOP’s with accepted control strategies and best practices.
• Play a priority role in operator training, assessment, and certification.
• Proper inspection of the kiln workshops during failures and turn around maintenance
• Optimize the production process using control loops
• Develop control room operators and production supervisor’s competencies, coaching sessions and training modules
• Create, update, and validate all production standard operation procedures (SOP) for all production jobs.
• Participate actively in plant performance and plant reliability meetings
• Apply effective coaching techniques in on the job training with CCROs and Shift Production
• Report and investigate accidents and near misses with accident investigation committee.
• Support the Production Manager in preparation of department operation budget, monthly accruals and capital projects.
• Work with section/ senior engineers in planning and scheduling of major and minor plant maintenance / shutdowns.
• Maintain a tool inventory used by production personnel
• Maintain and administer monthly shift roster and leave roster
• Support the Production Manager in the development and implementation of training plans for the production personnel
• Identify training needs of Shift personnel, guide and train them
• Appraise subordinates and recommend promotions, transfers and disciplinary actions,
• Compile on daily basis job done during major repairs and discuss with Methods the execution of outstanding jobs for the incoming team
• Monitor the cost of production and expenditures in order to optimize the cost per ton of clinker and cement.
• Support the Production Manager in the manpower planning and development.
• Ensure compliance with environmental and quality management systems (ISO 14001 & 9001 -2000).
• Ensure the plant surroundings are in a good environmental state always
• Ensure the efficiency and effectiveness of subordinates and instill discipline from time to time.
• To maintain the quality within the range as defined in the Quality Management System (QMS)
• Monitor the production results (production amount, energy consumption, etc.) in order to meet the target KPIs.

Requirements
What we are looking for:

• Degree or equivalent in any Engineering discipline (Mechanical / Electrical Engineering as main subjects)
• Minimum of 4 years cognate experience in Cement Manufacturing industry
• Strong knowledge of HSE standards
• Deep understanding of cement manufacturing process (kiln, raw mill, clinkerization)
• Strong Analytical & Root Cause Capability
• Safety & Environmental Leadership
• Training & Coaching Excellence
• Strong Documentation & Governance Discipline.