Packing Plant CCR Operator at Adept Systems

Key Responsibilities

Rotary Packer Operation & Control

• Operate and monitor rotary packers (Ventomatic or Haver & Boecker equivalent), conveyors, air slides, bag applicators, and reject systems via the CCR.
• Maintain target packing rates (tph) and ensure optimal utilisation of all packing lines throughout the shift.
• Monitor and control bag weight accuracy within specified tolerances, initiating corrective adjustments as required.
• Respond to packer alarms, bag rejection spikes, and line stoppages promptly, coordinating with field operators to restore normal operation.
• Coordinate packer start-up and shutdown sequences in line with standard operating procedures.

Bulk & Bag Dispatch Coordination

• Coordinate bulk and bagged cement dispatch activities in alignment with daily sales orders and dispatch schedules.
• Liaise with the dispatch team to confirm truck loading sequences, product allocations, and loading bay assignments.
• Monitor truck turnaround times (TAT) within the packing and dispatch area and flag delays or bottlenecks to the Shift Coordinator.
• Ensure dispatch documentation including loading sheets, weighbridge tickets, and delivery notes are verified and accurate prior to truck departure.
• Communicate dispatch status updates to the supply chain and customer service teams in a timely manner.

Silo Level Monitoring & Product Changeover Management

• Monitor cement silo levels continuously and coordinate feed and extraction sequences in line with production and dispatch requirements.
• Execute product changeover activities between cement grades following defined SOPs to eliminate cross-contamination.
• Coordinate silo switching decisions with the Shift Coordinator and supply chain team to align with dispatch priorities.
• Maintain accurate silo allocation and grade identification records throughout the shift.
• Escalate low silo levels or supply disruptions to the Shift Coordinator promptly to prevent dispatch interruptions.

Compressed Air & Pneumatic Conveying System Management

• Monitor compressor performance, compressed air system pressure, and air slide operation to ensure uninterrupted cement conveying to packing lines.
• Identify and report compressed air leaks, pressure drops, or conveying system blockages and coordinate corrective actions with maintenance.
• Optimise compressed air usage and compressor loading to minimise specific energy consumption within the packing plant.
• Monitor dust extraction and filter systems to ensure effective dust suppression and compliance with emission standards.

Packing Plant Manpower Supervision

• Supervise packing plant operators, bag attendants, palletisers, and cleaners assigned to the shift, ensuring effective task allocation based on operational priorities.
• Enforce discipline, accountability, and performance standards throughout the shift.
• Conduct routine field inspection rounds to verify compliance with operational procedures and equipment status.
• Mentor junior operators and promote skill development, process awareness, and safety culture within the team.
• Coordinate handover briefings at shift changeover to ensure complete and accurate status communication to the incoming team.

Quality Assurance & Dispatch Accuracy

• Ensure the correct cement grade is packed and dispatched in accordance with customer order specifications at all times.
• Coordinate with the QA/QC laboratory for product quality verification and prompt feedback on any out-of-specification results.
• Monitor bag weight statistics and reject rates, escalating trends that indicate packer calibration or feed issues.
• Enforce grade segregation and product identification protocols throughout packing and loading operations.
• Escalate quality non-conformances or dispatch errors to the Shift Coordinator immediately.

Documentation & Shift Reporting

• Maintain accurate and up-to-date shift logs covering packing volumes, downtime events, equipment status, and process deviations.
• Prepare and submit comprehensive shift production and dispatch reports to the Shift Coordinator at the end of each shift.
• Complete shift handover documentation thoroughly, ensuring the incoming CCR Operator is fully briefed on plant status, outstanding issues, and pending actions.
• Update production and dispatch data in plant reporting and ERP systems accurately and on time.

Health, Safety & Environmental Compliance

• Ensure all packing plant and dispatch operations are conducted in full compliance with Savannah Cement HSE policies and statutory requirements.
• Enforce Lock-Out/Tag-Out (LOTO) procedures during all maintenance interventions on controlled packing plant equipment.
• Lead shift safety briefings, toolbox talks, and pre-task risk assessments for the packing plant team.
• Monitor dust extraction systems and prevent unsafe dust accumulation in packing and dispatch areas.
• Stop unsafe operations immediately and escalate to the Shift Coordinator without delay.
• Report all incidents, near-misses, and HSE non-compliances promptly and support investigation processes as required.
• Promote strong housekeeping standards and a culture of safety awareness within the packing and dispatch areas.

Maintenance Coordination & Equipment Reliability

• Liaise with the maintenance team to communicate equipment defects, packer faults, and repair requirements identified during the shift.
• Follow up on outstanding maintenance work orders that affect packing line availability or throughput performance.
• Support planned maintenance shutdown preparations by coordinating equipment isolation and safe handover from the CCR.
• Escalate recurring equipment failures and reliability concerns to the Shift Coordinator for engineering review.

Coordination with QA/QC, Maintenance & Dispatch Teams

• Maintain continuous communication with QA/QC to ensure timely product testing, quality clearance, and grade confirmation before dispatch.
• Coordinate with the maintenance team on priority defect rectification to minimise packing line downtime.
• Liaise with the dispatch and supply chain team to align packing priorities with daily dispatch plans and customer delivery schedules.
• Escalate unresolved inter-departmental coordination issues to the Shift Coordinator for timely resolution.

Academic and Professional Qualifications

• Bachelor's degree or Diploma in Chemical Engineering, Process Engineering, Mechanical Engineering, Electrical Engineering, or Mechatronics Engineering
• Minimum of 5 years of hands-on experience in cement packing plant operations, with demonstrated CCR or supervisory responsibility.
• Hands-on experience operating rotary packer systems (Ventomatic, Haver & Boecker, or equivalent) is required.
• Proficiency in operating DCS/SCADA control systems; ability to navigate process schematics, alarm panels, and trend data.
• Strong understanding of pneumatic conveying systems, compressed air management, and dust extraction operations.
• Experience with bulk loading systems and weighbridge-integrated dispatch operations is an added advantage.
• Supervisory experience in a shift-based manufacturing environment is an added advantage.
• Familiarity with SAP Plant Maintenance or equivalent ERP/CMMS for downtime and production reporting is advantageous.