General Superintendent - Anode Baking
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Key skills for this role
About the Role
EGA seeks a General Superintendent for Anode Baking at Al Taweelah to plan, control, and manage Paste Plant operations. The role ensures cost-effective supply of raw materials for aluminium smelting, oversees production, quality, safety, and team development.
Key Skills for This Role
Responsibilities
- Plan, control, monitor and manage the effective operation of Paste Plant Line 1, Line 2 and Line 3 at Al Taweelah site
- Ensure timely and cost effective supply of quality raw materials used in aluminium smelting process
- Maintain optimum inventory levels while achieving operational efficiency and cost effectiveness
- Ensure all EHS procedures, policies, practices and systems are in place and adhered to
- Establish systems for forecasting and controlling environmental emissions and waste generation
- Ensure 5S standards are maintained throughout the year
- Establish systems for understanding customer requirements and ensure delivery of high quality products
- Prepare annual green anode production plans aligned with EGA’s strategic vision
- Establish and implement quality control systems to monitor deviations from operating parameters
- Establish financial strategies for Paste Plants and monitor financial performance
- Define skills and competency requirements and drive recruitment and personnel development
- Drive implementation of Performance Management, Talent Management and Development Planning processes
Requirements
- Graduate Engineer / Diploma of Associate Engineer
- Graduate Engineer with 5 years of experience in a similar position, or Diploma of Associate Engineer with 10 years of experience in a similar position within a continuous manufacturing environment
- Preferably experience in an Aluminium Smelter
- Good understanding of mechanized manufacturing plants including pneumatic and hydraulic systems, conveyors, elevators, crushing and dedusting systems
- Strong interpersonal skills, computer literacy and sound knowledge of ISO standards
Full Job Posting
JOB PURPOSE
- Plan, control, monitor and manage the effective operation of Paste Plant Line 1, Line 2 and Line 3 at the Al Taweelah site.
- Ensure the timely and cost effective supply of quality raw materials used in the aluminium smelting process.
- Maintain optimum inventory levels while achieving operational efficiency and cost effectiveness.
KEY ACCOUNTABILITIES
- Ensure all necessary EHS procedures, policies, practices and systems are in place across both Paste Plant phases.
- Demonstrate effective EHS leadership within the department.
- Establish systems for forecasting and controlling environmental emissions and waste generation.
- Conduct drills and training to ensure employee readiness during emergency situations.
- Ensure 5S standards are maintained throughout the year across all areas.
- Establish systems for understanding customer requirements and documenting them through Service Level Agreements.
- Ensure delivery of high quality products in a sustainable, consistent and cost effective manner.
- Lead the team in upgrading and improving existing plant setups and processes based on customer requirements.
- Ensure standard operating procedures, manuals and training procedures are established and adhered to.
- Formulate and align operational best practices and departmental objectives with EGA vision and strategic goals.
- Support documentation related to EGA policies concerning patents, copyrights and new suggestions.
- Ensure effective implementation and compliance with EHS standards, management systems, ISO and OHSAS requirements.
Production
- Define and control the required inventory levels of green anodes across both phases.
- Prepare annual green anode production plans aligned with EGA’s strategic vision.
- Ensure cost effective execution of approved production plans across all three Paste Plant lines.
- Provide realistic estimates of raw material consumption required to produce the targeted number of green anodes.
- Establish effective production management across the three Paste Plant lines with varying anode configurations.
- Implement FM Global recommendations to ensure risks and fire protection systems comply with standards.
Quality Management
- Establish and implement quality control systems to monitor deviations from operating parameters and quality standards.
- Stay updated on technical developments within the area of operation and drive process development initiatives.
- Promote process improvements and best practices through evaluation and analysis of plant performance.
- Conduct regular meetings with Paste Plant Supervisors to review quality parameters and drive continual improvement.
Budget and Financial Control
- Establish financial strategies for Paste Plants in line with plant and departmental strategic objectives.
- Monitor financial performance and ensure achievement of budgeted KPI targets through Balanced Scorecards, Dashboards and Monthly Review Meetings.
- Manage the implementation of business systems related to lean manufacturing, Kaizen events and participation in suggestion schemes.
- Drive synergies across both phases to improve financial performance through cash generation, cash conservation and cost reduction initiatives.
- Contribute to reducing the unit cost per ton of anodes and support budget planning activities.
Training and Development
- Define skills and competency requirements and drive recruitment and personnel development.
- Drive implementation of Performance Management, Talent Management and Development Planning processes.
- Promote innovation and creativity while encouraging participation in business excellence initiatives.
- Ensure EGA’s core values are effectively communicated, understood and practiced throughout the department.
- Manage National employee and Graduate Training Programs and conduct quarterly progress reviews.
- Work closely with Process Control Engineers to improve quality related knowledge among supervisors and employees.
- Ensure employees are trained to achieve capability requirements equivalent to at least 30% of the next grade level.
AUTHORITY / DECISION MAKING
- Take full responsibility for designing and redesigning business systems across the three Paste Plant production lines producing more than 780,000 green anode blocks.
- Establish annual financial strategies covering Budget, Capex and Spare Parts expenditure.
- Define and control healthy inventory levels of green anodes to support continuous operation of Reduction Cells.
- Ensure effective silo management to maximize the benefits of incoming raw material quality.
- Direct manufacturing activities across both Paste Plants to maximize productivity, quality and business continuity.
- Exercise final authority on all issues related to Green Plants across all three production lines at Al Taweelah.
- Ensure effective implementation of safe operating procedures due to high fire risk associated with combustible materials.
- Receive guidance and instructions from the Senior Manager – Paste Plants & Projects as required.
- Perform duties in accordance with Delegation of Authority, procedures and company policies.
QUALIFICATIONS & SKILLS
- Graduate Engineer / Diploma of Associate Engineer.
- Graduate Engineer with 5 years of experience in a similar position, or Diploma of Associate Engineer with 10 years of experience in a similar position within a continuous manufacturing environment, preferably in an Aluminium Smelter.
- Good understanding and working knowledge of mechanized manufacturing plants, including pneumatic and hydraulic systems, chain and belt conveyors, elevators, crushing systems and dedusting systems.
- Strong interpersonal skills, computer literacy and sound knowledge of ISO standards.
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