Manufacturing Performance Optimization:

Develop and implement strategies to enhance clinker-to-cement conversion efficiency, energy utilization, and overall plant performance.

Monitor key performance indicators (KPIs) across cement plants, providing insights to drive continuous improvement in production and logistics.

Benchmark plant performance against industry standards to identify gaps and implement corrective measures for enhanced productivity.

Process Standardization and Best Practices:

Establish and enforce standardized operating procedures (SOPs) across cement plants to ensure consistency in raw material usage, grinding efficiency, and product quality.

Identify and implement best practices in kiln operation, pyro-processing, and cement milling to enhance production efficiency and sustainability.

Conduct periodic process audits and technical reviews to ensure adherence to best practices and identify areas for further refinement.

Data-Driven Decision Making:

Analyze production, maintenance, and quality data to identify bottlenecks, operational inefficiencies, and areas for improvement in cement manufacturing.

Develop real-time dashboards and reporting mechanisms for plant managers and leadership to make data-backed decisions.

Implement predictive analytics models to anticipate equipment failures, optimize raw material usage, and enhance process reliability.

Cost Efficiency and Optimization:

Identify cost reduction opportunities in fuel consumption, raw material procurement, and logistics through process improvements and waste minimization.

Optimize energy consumption, clinker factor, and alternative fuel usage to reduce operational costs while ensuring product quality.

Drive initiatives for reducing specific energy consumption (SEC) and increasing the use of waste heat recovery systems to improve cost efficiency.

Compliance and Regulatory Adherence:

Ensure strict adherence to environmental regulations, pollution control norms, and safety standards as per cement industry guidelines.

Conduct regular audits and compliance checks across cement plants to mitigate risks and maintain legal and regulatory adherence.

Develop risk mitigation frameworks to address potential compliance breaches, ensuring robust reporting and corrective action mechanisms.

Cross-Functional Coordination for Plant Efficiency:

Act as the central coordinating authority between cement plants, facilitating knowledge sharing and standardized problem-solving approaches.

Collaborate with functions such as quality control, procurement, and logistics to ensure smooth plant operations and supply chain management.

Facilitate inter-plant benchmarking exercises to drive synergies and enhance overall operational efficiency.

Technology and Innovation:

Drive the adoption of advanced process control systems, automation, and digital transformation initiatives to optimize cement plant operations.

Evaluate and implement AI-driven analytics, alternative energy sources, and IoT-based monitoring solutions for efficiency improvement.

Foster a culture of innovation by engaging with technology partners, research institutions, and internal teams to explore emerging trends in cement manufacturing.

Training and Capability Building:

Develop specialized training programs focusing on kiln operation, clinker production, cement grinding, and quality control best practices.

Organize workshops to upgrade skills in predictive maintenance, process optimization, and new cement manufacturing technologies.

Establish a structured competency development framework to ensure continuous learning and upskilling of plant personnel.

Risk Management and Internal Controls:

Identify operational risks, such as equipment failures, supply chain disruptions, and regulatory non-compliance, and implement control measures.

Establish preventive maintenance schedules and real-time monitoring systems to minimize production downtime and operational inefficiencies.

Develop contingency plans for unforeseen disruptions, ensuring business continuity and resilience in plant operations.

Stakeholder Management and Reporting:

Prepare and present detailed performance reports, operational reviews, and strategic recommendations to senior leadership and plant heads.

Maintain strong relationships with raw material suppliers, industry regulators, and internal stakeholders to ensure smooth business operations.

Engage with government agencies and industry bodies to stay updated on policy changes, regulatory requirements, and sectoral developments.

 

Key Stakeholders - Internal:

Chief Manufacturing Officer (CMO)

Chief Operations Manager (COM)

Chief Plant Manager (CPM)

Production Heads

Production Head

Maintenance Head

Head CPP

Head (QC)

Head WHRS

Cluster HR Head

Unit Finance Controller

Plant Manager

HR & Training Teams

Key Stakeholders - External:

Industry Associations & Regulatory Bodies

Digital & Process Automation Solution Providers

Energy & Sustainability Consultants

Supply Chain & Logistics Partners

 

Education Qualification:

B.Tech in Mechanical Engineering, Chemical Engineering, or a related field. A Master’s degree in Operations or Business Administration is preferred.

Work Experience:

15+ years of experience in cement manufacturing, process optimization, and plant performance management, with a track record of driving efficiency improvements.

Industry Knowledge:

In-depth expertise in clinker-to-cement conversion, kiln operations, energy optimization, and regulatory compliance in the cement industry. Familiarity with digital transformation, AI-driven analytics, and sustainability practices in manufacturing.