Senior Process Engineer (JR10001773) Mold, Wales
The role holder is responsible for:
* Monitor and optimize the kiln and cement lines, from raw materials to finished product.
* Improve the operating efficiency of the pyro, comminution and associated equipment – to include reduction of air usage and false air, reduction of electricity and fuels, increasing alternative fuels, increasing alternative raw material consumption, reduction of water usage.
* Report to management team on performance against KPIs and other key metrics.
* Set process related targets for operational staff.
* Design and implement progressive, costed and planned improvements to the mills and kiln efficiencies; to include mill and kiln inspections and associated studies.
* Develop and train staff in kiln and comminution process to put in place skills for future business needs.
* Verify that equipment is maintained in the proper original condition.
* Verify that equipment is being operated in accordance with the OEM recommendations or as per Plant Manager/HOPExUK recommendations.
* The reporting and accuracy of all process related KPI data and other internal reports as required.
* The completion of regular kiln and cement line process inspections and the keeping of accurate records at a frequency agreed with the plant manager and head of operational excellence.
* Improving and optimizing the process based on the above and other process data.
* Providing solutions for operational problems.
* Gathering, collating and analyzing process and downtime information on kiln line and cement mills and associated equipment.
* Monitoring and reporting on the consumption of raw materials, fuel, power, water, and air.
* Working with departmental teams to identify and implement efficiencies in the consumption of fuel, power, water, and air.
* Writing, maintaining, communicating, and training SOPs for the Comminution and Pyro lines and ensuring that they are reviewed on a yearly basis.
* Conducting Heat and Mass Balance for Comminution and Pyro lines.
* Taking full responsibility to achieve +95% of process optimiser utilization (Expert system).
* Designing and implementing progressive, costed and planned improvements to the kiln and cement line efficiencies.
* Assisting other departments in reaching operational targets.
* Sharing best practice with other Heidelberg Materials cement plants on comminution and Pyro operation.
* Performing any other process efficiency related duties as reasonably required by line management.
* Providing ongoing operational support to the plant for all shifts by participating in the plant’s on-call program. This includes evaluating and determining the course of action for incidents after hours and on weekends while on call and may require on-site supervision of the resolution to maintain operational efficiency.
* Actively involve during all the Plant shutdowns and support the production team to achieve all the tasks including refractories requirement and installation.
* Assessing potential alternative raw material, fuels, and additives for improvements to improve efficiency and cost reductions via trials.
* Support project implementation by taking the process lead.
What’s on Offer:
Salary: Competitive Salary
•Employer of choice: Armed Forces Covenant (Silver) / Disability Confident Committed / 5% Club (Platinum) / Mates in Mind / Clear Assured (Foundation) / The Mineral Products and Qualification Council (MPQC) / STEM Ambassador
•Work Life Balance: 27 days holiday (excluding bank holidays) / Agile working / Flexible working / Holiday purchase / Sabbatical
•Family Friendly: Enhanced policies such as Maternity / Paternity / Parental Leave / Neonatal / Adoption/IVF/Menopause
•Social Value: paid Volunteering Day every year / Communities (LGBTQ+, Network of Woman, Woman in Science and Engineering (STEM), Armed Forces)
•Wellbeing: Employee Assistance Programme (EAP) / Mental Health First Aiders / Cycle to Work / Employee Benefits portal including Gym discount / Free eye tests / Discounted Private Medical cover
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