Role Purpose
The purpose of the role is to ensure the safe, efficient and reliable operation of the plant through a comprehensive working knowledge of manufacturing equipment and processes. The Process Aide serves as a production inspector, monitoring equipment and process conditions, identifying operational issues and taking appropriate corrective actions to maximise plant efficiency.
The role is responsible for supporting the safe and efficient start-up, operation and troubleshooting of plant equipment, as well as participating in planned shutdowns and routine maintenance activities.
The Process Aide is also responsible for ensuring the smooth operation, cleanliness and general housekeeping of all production areas, while maintaining required safety and operational standards.
Key Responsibilities
Perform all tasks in a safe and efficient manner.
Carry out equipment energy isolation in accordance with LOTOTO procedures.
Perform field checks and troubleshoot all aspects of the raw mill, kiln and finish mill systems in compliance with Company quality standards and requirements.
Conduct running and shutdown inspections of all equipment to identify defects and operational deviations, and report issues to the CCRO for appropriate action.
Prepare shift reports and complete the patroller inspection checklist, clearly indicating resolved problems and outstanding issues across the plant.
Monitor equipment operation and troubleshoot problems throughout the plant, including process drift, preheater blockages and other operational issues.
Perform first-level maintenance activities throughout the plant as required to maximise equipment availability and minimise downtime.
Coordinate the activities of mobile plant operators and other contracted service providers to ensure an adequate supply of process-related materials.
Operate individual equipment in test mode when such equipment is undergoing maintenance.
Assist the CCRO in operating key equipment in local mode and off-specification product management.
Carry out diaphragm slot cleaning for finish mills during maintenance days.
Carry out ball mill media loading in accordance with the Process Engineer's recommendations.
Conduct test drilling of refractory lining and submit reports to the CCRO for analysis.
Ensure the smooth operation of plant air compressors and pneumatic conveying systems.
Maintain good housekeeping standards throughout the plant.
Attend and contribute to safety toolbox meetings at the beginning of each shift and provide suggestions on safe working methods.
Implement Company Safety Rules and Regulations in accordance with Group HSE Standards and Advisories.
Monitor and optimise the operation of raw mills and kiln systems in compliance with Company quality standards and requirements.
Supervise the activities of contractors and third-party operators through the effective implementation of the Contractor Safety Management (CSM) Standards.
Monitor production activities to ensure compliance with Group Environmental Standards and maintain good housekeeping at all times.
Monitor the loading and off-loading of alternative fuels and other solid fuels within the plant.
Participate in plant turnaround maintenance, root cause analysis and other Company best practices, including test drilling, wrecking and bricklaying activities.
Contribute to maintaining equipment in good working condition through effective first-level inspections and regular monitoring.
Inspect equipment before and after use to identify potential problems and liaise with the Maintenance Department to ensure appropriate corrective actions are taken.
Carry out first-level inspections of all equipment and recommend actions to improve equipment reliability and performance.
Ensure the safety of personnel and equipment at all times.
Comply with EMS Production Instrumentation activities and requirements.
Support the implementation and maintenance of the Integrated Management System (IMS) within the plant.
Requirements
Critical Knowledge
Good knowledge of applicable safety laws, regulations and standards.
Working knowledge of cement manufacturing processes, including raw meal preparation, burning, combustion, grinding and packing operations.
Familiarity with material conveying systems and methods used in cement manufacturing.
Working knowledge of plant and equipment operating procedures.
Critical Experience
2 - 5 years of relevant post-graduation experience, preferably in a cement manufacturing or similar industrial environment.
Demonstrated practical knowledge of mechanical and electrical systems, with the ability to perform a range of basic mechanical and electrical tasks.
Experience operating mobile equipment, including Bobcat and forklift.
Ability to perform physically demanding tasks, including heavy lifting, for extended periods where required.
Educational Qualifications
Bachelor's Degree in Mechanical or Electrical Engineering.