Open Roles at Bamburi Cement Ltd

THE OPPORTUNITY

• In collaboration with maintenance, quality and process departments, the Clinker Production Engineer role drives operational excellence in clinker production and alternative fuels utilization through achievement of target volumes at the right quality, cost, safely and in an environmentally sound manner. The role also drives the sustainable refractory strategy taking into account clinker demand and cost.

YOUR RESPONSIBILITIES

People, Capability & Culture

• Build a high performing, professional and customer centric team.
• Develop succession, capability and leadership pipelines while optimising use of external expertise.
• Embed a performance-driven, ethical and safety-conscious culture
• Embed a culture of continuous improvement and operational excellence

Health Safety & Environment (HSE)

• Effectively communicate and engage all employees and contractors under their supervision to ensure comprehensive understanding and adherence to the Company’s HSE Policy, HSE Rules and HSE Standards.
• Provide strong leadership in promoting a safety-first culture among workers and contractors, encouraging active participation in safety initiatives, programs, incident investigation and fostering anenvironment where safety is everyone’s responsibility.

Clinker Production KPI’s

• Ensure that clinker production operations are in compliance with the Bamburi Cement’s Health, Safety and Environment rules and policies, operating procedures (SOPs).
• Cascades the clinker production alternative fuels utilization plan for execution and spearheads targets achievement
• Manages clinker production cost (variable and fixed) and take necessary actions to meet budget
• Ensuring production standard operating procedures are followed and reviewed from time to time.
• Ensures the clinkering plants, coal grinding, and Alternative fuels plants are operated with safe limits
• Participates and contributes in planning activities by collaborating with Preventive maintenance to ensure the maintenance planning is well synchronised with clinker plants (coal mill, kilns and clinker loading) operations and that activities planned for are executed.
• Spearheads Production related Root Cause analysis for shops under his responsibility in a cross-functional forum and leads in actions implementation. Participates in all other (maintenance) root cause investigation for his shops.
• Routinely monitors stocks of all clinker production materials and fuels (both local and imported) and other production supplies to guarantee sufficiency and no stock outs. Works closely with supply chain and quarry departments to ensure reasonable stocks of raw materials and products in order to keep the balance of supply and demand.
• Drives continuous improvement agenda for the process and equipment by analyzing performance gaps, identifying improvement opportunities and ensuring implementation of improvement action plans.
• Manages refractory management system in view of operations mastery. Ensures proper control and monitoring of refractory conditions in collaboration with the refractory engineer and provides feedback for refractory improvement actions and maintenance planning
• Is responsible for developing & maintaining technical training material in the clinkering section to enhance knowledge development.
• Implements the First level inspection program by shift operators and ensures its efficiency.
• Support Production manager in the yearly budget, financial planning, and forecast of the production department along with the technical direction.
• Providing the technical support for the optimization of the raw meal production, kiln and coal mills with the minimum costs.
• Works with production manager and HR department in planning for Production staff training and development.
• Leads in the alternative fuels initiatives implementation in the plant. Ensures achievement of target Thermal Substitution rate

YOUR QUALIFICATIONS, EXPERIENCE & SKILLS

Minimum Requirements:

Qualification & Experience

• Bachelor degree of Engineering or Science preferably Chemical/Process engineering
• 5-7 years’ experience in the industrial sector preferably in cement industry on a position of similar responsibility
• In depth understanding of refractory management in the cement environment
• Cement and clinker manufacturing expertise with in-depth knowledge of plant operations and process engineering
• Detailed knowledge of industrial safety management especially process safety management

Generic Skills

• Communication skills, planning and organizing skills, strategic planning, problem solving skills, multiple tasking skills, leadership skills and PC skills.

Leadership Skills

• People Management & Development
• Emotional Intelligence
• Decision Making
• Conflict Management
• Adaptability & Learning Agility
• Delegation & Empowerment

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THE OPPORTUNITY

The quality control shift operator is responsible for;

• Controlling & monitoring the quality of materials from quarry up to dispatched cement.
• Ensuing accurate and timely analysis of the different samples picked during shift and update the records as per the quality plan guidelines.
• Implementing cost reduction initiatives in line with BU and Plant objectives.
• Supporting the plant to achieve burning efficiency, kiln reliability, production cost efficiency , process efficiency and product quality performance.

YOUR RESPONSIBILITIES

People, Capability & Culture

• Demonstrate professionalism, integrity and respect in all interactions with colleagues, contractors and stakeholders.
• Take ownership of personal performance, productivity and quality of work.
• Actively participate in learning, training and capability-building initiatives relevant to the role.
• Collaborate effectively with team members to support delivery of team, site and organization objectives.
• Model ethical behaviour and speak up when behaviour or practices are inconsistent with company values.
• Contribute ideas, suggestions and participate in continual improvement initiatives.

Health Safety & Environment (HSE)

• Comply fully with the Company’s HSE Policy, Rules and Standards at all times.
• Perform work strictly in accordance with approved procedures, permits and risk assessments.
• Use required personal protective equipment (PPE) correctly and consistently.
• Actively identify, report and where possible correct unsafe acts, unsafe conditions and environmental risks.
• Promptly report all incidents, near misses, hazards and at-risk conditions.
• Participate in tool box talks, safety briefings, drills and HSE improvement initiatives.

MAIN ACTIVITIES

• Participate in environmental activities in the plant and laboratory i.e.ensure clean working areas (benchtops, machines and sampling points) and segregation of waste according to plant guidelines on environmental management systems.
• Sample, analyse and control each stage of the cement making and dispatch process in the plant according to the Quality control plan, record the results and communicate with the stakeholders (CCR, Quarry, Dispatch).
• Right decision at the right time to meet the QC set point of raw mix or cement additives and improve the clinker and cement uniformity. Control and track personal performance with regards to daily, weekly and monthly uniformity KPIs.
• Ensure that all the tests are performed as per EN and KS standards, LQTS and laid down procedures to assure accuracy and measurement integrity.
• Investigate quality incidences/deviations (product and manufacturing) during the shift operations and take corrective actions to prevent dispatch of nonconforming products.
• Follow and implement Laboratory documentation (LQTS, Analysis methods, Quality control sop’s etc) and cascade to stakeholders.
• Ensures accuracy of data entry and storage in the provided data storage tools (LIMS,excel, telegram).
• Perform equipment stability checks and sample preparation checks for lab instrumentation as part of Lab Equipment Reliability Index (LERI) tracking.
• Implement cost reduction initiatives in the use of purchase of laboratory consumables and equipment.
• Participate in implementation of ISO management systems in the plant.
• Acts as Physical lab analyst backup or Day analyst back up by performing roles of these positions when assigned .

YOUR QUALIFICATIONS, EXPERIENCE & SKILLS

Minimum Requirements:

• Degree in Industrial/Analytical Chemistry or Chemical and Process Engineering
• 2 years experience in a quality control laboratory preferably in a busy manufacturing industry.

Generic Skills

• Analytical thinking, Adaptability & learning agility, Management skills, Communication, Planning & organizing skills.

Technical Skills

• Good knowledge and understanding of physical and chemical properties of cement.
• Good knowledge of methods and techniques used in chemical and physical laboratory analysis of cement.
• Good knowledge of laboratory equipment instrumentation quality assurance.
• Basic understanding of cement making chemistry.
• Good knowledge of laboratory safety and environmental good practices.
• Good knowledge of laboratory equipment calibration methods.
• Basic computer skills.
• Attention to details, accurate and precise in taking measurements.

Management Skills

• Team player.
• Good level of Integrity.
• Good organisation and communication skills.
• Attention to detail with keenness on accuracy / Precision.
• Adaptability and flexibility to different work conditions and requirements.
• Self Driven & Results oriented.