Kiln Coach, Mfamosing at Lafarge Cement

Summary

The responsibility of the kiln Coach is to guarantee efficiency and optimization of the burning line by working in conjunction with process, quality and maintenance team, 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 a continuous process of daily performance monitoring, evaluation and feedback, maintaining and improving the plant efficiency through analysis of specific process parameters and ensuring conformities with Safety, Environmental and Quality guidelines.

Responsibilities

• Performs all tasks in a safe and efficient manner.
• Analyzes all process incidents and work with CCRO to mitigate the impact of such incidents and propose solutions to prevent future reoccurrence.
• Monitors application of Production SOP’s.
• Coordinate the development of operational procedures (SOPs) for the execution of all production related tasks in the plant.
• Helps 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.
• Ensures alignment of SOP’s with accepted control strategies and best practices.
• Plays 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 supervisors 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

Administration:

• Report and investigate accidents and near misses with accident investigation committee.
• Assist the Production Manager in preparation of department operation budget, monthly accurals and capita; 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
• Assist the Production Manager in the development and implementation of training plans for the production personnel
• Detect training needs of Shift personnel, guide and train them
• Appraise subordinates and recommend promotions, transfers and disciplinary actions,
• Compiles on daily basis job done during major repairs and discuss with Methods the execution of outstanding jobs for the incoming team.
• Monitors the cost of production and expenditures in order to optimize the cost per tonne of clinker and cement.
• Assist the Production Manager in the manpower planning and development.
• Ensures compliance with environmental and quality management systems (ISO 14001 & 9001 -2000).
• Ensures the plant surrounding are in good environmental state at all times
• Ensures 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.
• This list of responsibilities is not exhaustive and the job holder may be required to perform duties outside of this as operationally required

Job Dimensions

• Sales, number of people, budget, volumes, etc.
• Sales: 3m tons of cement /annum Volumes: 2.5m tons of clinker and 3m tons of cement grind per annum

List of Direct Reports

• CCROs

Key interfaces, stakeholders and relationships:

• The incumbent interacts regularly with all cadres of staff.
• Report to Production Manager, Interface with the following: Process, Mechanical, Methods, Electrical, Automation, Safety, Quarry, and Stores departments

Key Performance Indicators(KPIs)

• Zero LTI
• Volume target
• Quality Target maintained
• STEC target
• Mills and kilns PRI
• SEEC target
• No of refractory failures

Educational Qualification & Experience

• First degree or equivalent in any engineering discipline (mechanical /electrical engineering as main subjects)
• 5 to 7 years’ experience in Control Room Operations (VRM, CSM, Kilns)
• CRO Certified 

Technical / Functional Skills:

• Good written and oral communication skills
• Strong computer Skills especially Excel, word, PowerPoint and email applications
• Ability to prioritize with excellent time management skills
• Good attention to detail
• People management skills

Behavioral competence:

• Good interpersonal skills
• Strong team player
• Adaptable
• Tact and tolerant
• Ability to work well under pressure and adhere to set deadlines
• Resilient and Motivated

Leadership and managerial abilities:

•  Excellent management skills and ability to organize and plan effectively to meet both short and long range goals and objectives.
• Ability to manage multiple project plans successfully and simultaneously.
• Ability to motivate individuals and teams
• Able to coach and direct a diverse team