General Superintendent - Anode Baking

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

Environment, Health, Safety and Sustainability

• Ensure all necessary Environment, Health & Safety (EHS) procedures, policies, practices and systems are in place across both Paste Plant phases in line with Company Policy and are adhered to in order to provide a safe working environment with minimal risk.


• Demonstrate effective EHS leadership within the department.


• Establish systems for forecasting and controlling environmental emissions and waste generation, and review targets in line with smelter objectives to ensure compliance with legal and process requirements.


• Conduct drills and training to ensure employee readiness during emergency situations and control potentially dangerous situations.


• Ensure 5S standards are maintained throughout the year across all areas to improve productivity, enhance safety and reduce waste.

Customer Focus

• Establish systems for understanding customer requirements and documenting them through Service Level Agreements, periodically review them and ensure compliance through feedback mechanisms.


• 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 and conduct related studies.

Policies and Procedures

• Ensure standard operating procedures, manuals and training procedures are established, effectively communicated and adhered to.


• Formulate and align operational best practices and departmental objectives with EGA vision and strategic goals, addressing both short- and long-term priorities for Paste Plants (L-1, L-2 and L-3), and ensure clear communication across the team.


• Support documentation related to EGA policies concerning patents, copyrights and new suggestions when required.


• Ensure effective implementation and compliance with EHS standards, management systems, ISO and OHSAS requirements in line with the EGA framework.

Production

• Define and control the required inventory levels of green anodes across both phases to support consistent operations while considering financial and risk management factors.


• Prepare annual green anode production plans aligned with EGA’s strategic vision, with flexibility to adjust based on operational requirements and contingency plans.


• Ensure cost-effective execution of approved production plans across all three Paste Plant lines and different anode configurations, with periodic reviews to support business requirements and Potline technologies across both sites.


• Provide realistic estimates of raw material consumption required to produce the targeted number of green anodes for hot metal production.


• Establish effective production management across the three Paste Plant lines with varying anode configurations and raw material suppliers to maintain preventive maintenance schedules, optimize material utilization and consistently achieve OEE targets.


• Implement FM Global recommendations to ensure risks and fire protection systems comply with applicable standards and regulations.

Quality Management

• Establish and implement quality control systems to monitor deviations from operating parameters and quality standards, ensuring timely corrective and preventive actions for the cost-effective production of quality anodes.


• 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 and adherence to effective quality control systems.


• 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 to define, monitor and control Budget, Capex and related expenditures without compromising operational security.


• 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 when required.

Training and Development

• Define skills and competency requirements and drive recruitment and personnel development to ensure efficient plant operation within approved FTE and overtime limits.


• Drive implementation of Performance Management, Talent Management and Development Planning processes to enhance employee satisfaction and skills development.


• Promote innovation and creativity while encouraging participation in business excellence initiatives such as Suggestion Schemes, RCM, 5S and EHS programs.


• 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, with assets exceeding USD 375 million.


• Establish annual financial strategies covering Budget, Capex and Spare Parts expenditure while maintaining operational security and competitiveness.


• Define and control healthy inventory levels of green anodes to support continuous operation of Reduction Cells with different technologies while balancing financial and risk considerations.


• Ensure effective silo management to maximize the benefits of incoming raw material quality and support premium metal production.


• Direct manufacturing activities across both Paste Plants to maximize productivity, quality and business continuity while maintaining compliance with regulatory and EHS requirements.


• 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 the high fire risk associated with combustible materials such as HTM oil, Pitch and Coke.


• 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

Qualifications

• Graduate Engineer / Diploma of Associate Engineer.

Experience

• 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.

Skills

• 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.