Production Manager 10000 TPD cement plant.

 My duties include but not limited to the following: Can Operate kiln, Raw Mill and Cement Mills from CCR Responsible for kiln, Raw Mill and Cement Mill process and operation to achieve the production targets and KPI by optimizing the (kiln Raw Mill and Cement Mills) process including guiding for the CCR operators and training them on Kiln and Mill Trouble Shooting. Write the operation procedures for Kiln and Mills, Monitoring the kiln and Mill parameters to reach the max production and reducing energy consumption level. Analyze the process problems and find solutions for them and write RCA for problems. Training and evaluating CCR operators. Follow up for production Process and efficiency of the unit’s raw mill, kiln, cooler and cement mills on 24 hours basis. A regular and constant vigilance communication with quality control department to achieve the production targets according to quality control standards.  Supervising/coordinating with head of maintenance by scheduling maintenance stoppages. Supervising/coordinating with head of Electrical by scheduling maintenance work and calibration of instrument. Applying proper procedure (Burning and Grinding) with strict respect for the plant environment, safety and cement quality standards. Coordinating with Head of Quality Control regarding any important problem in the process line or quality control results. Supervising/coordinating of kiln shutdown mills shutdown for General Maintenance. Supervising/Coordinating Inventory of materials (Clinker, Lime stone, Gypsum and Iron ore etc :)  Supervising/coordination refractory requirement for Kiln, Cooler, TAD and Pre heater. Inspection of Refractory Bricks condition in Kiln, Cooler TAD and Preheater and make a plan for Schedule stoppage for Change. Supervising/coordination refractory Installation of Kiln, Cooler, TAD and Pre heater in annual Stoppages and in emergency Stoppages.

 Follow up for production Process and efficiency of the unit’s crusher, raw mill, kiln, cooler, cement mills and packing plant on 24 hours basis. Preparation of production plan according to production target set by higher management. Preparation of annual budget according to Production plan.. A regular and constant vigilance communication with quality control department to achieve the production targets according to quality control standards.  Supervising/coordinating with head of maintenance by scheduling maintenance stoppages. Supervising/coordinating with head of Electrical by scheduling maintenance work and calibration of instrument. Applying proper procedure (Burning and Grinding) with strict respect for the plant environment, safety and cement quality standards. Coordinating with Head of Quality Control regarding any important problem in the process line or quality control results. Supervising/coordinating of kiln shutdown mills shutdown for General Maintenance. Supervising/Coordinating Inventory of materials (Clinker, Lime stone, Gypsum and Iron ore etc. :) Monitor the refractory and insulation works for conformance with the provisions of the contract documents and the procedures manual.  Supervising/coordination refractory requirement for Kiln, Cooler, TAD and Pre heater. Inspection of Refractory Bricks condition in Kiln, Cooler TAD and Preheater and make a plan for Schedule stoppage for Change. Supervising/coordination refractory Installation of Kiln, Cooler, TAD and Pre heater in annual Stoppages.

 My duties include but not limited to the following: Daily production report preparation and management. Conducts shift turn-over by determining plant status at the start and end of shift. Identifies abnormalities or any unresolved problems to be communicated to the next shift and situations where information should be passed on to higher levels. Determine materials requirement based on production trend and other relevant factors. Guarantee adherence to the planned production plan as per manpower and materials resources. Complete all required documentation promptly and according to procedures. Ensure that any abnormalities and unresolved problems are documented in the shift report. Conducts regularly the routine roving inspections following established checklists. Identify situations where minor repairs can be carried out by production and coordinate with the Maintenance Department. Manage stockpiling of raw materials and silo levels for cement product. Oversees packing and shipping equipment to ensure smooth operations. Obtains periodic laboratory tests results and analyze by comparing to standards and targets. Take appropriate actions. Monitors throughput, identify opportunities and decide on changes in operating parameters to optimize output. Ensures that procedures are followed for the start-up and stop of mills. Recommends proposals that would enhance production capacity and efficiency. Directs the conduct of activities relative to the inspection of various equipment’s, flow of raw materials, other production-related activities and minor corrective repairs of machineries. Supervises CCR Operators reporting within the shift. Produces according to safety plans and address any identified situations. Ensures safe working conditions for all personnel within his place and time of duty.

 Follow up for production Process and efficiency of the unit’s crusher, raw mill, kiln, cooler, cement mills and packing plant on 24 hours basis. Preparation of production plan according to production target set by higher management. Preparation of annual budget according to Production plan. A regular and constant vigilance communication with quality control department to achieve the production targets according to quality control standards.  Supervising/coordinating with head of maintenance by scheduling maintenance stoppages. Supervising/coordinating with head of Electrical by scheduling maintenance work and calibration of instrument. Applying proper procedure (Burning and Grinding) with strict respect for the plant environment, safety and cement quality standards. Coordinating with Head of Quality Control regarding any important problem in the process line or quality control results. Grinding media calculation and control the Productivity of fully automatic and computerized grinding Station (Tube mill). Supervising/coordinating of kiln shutdown mills shutdown for General Maintenance. Supervising/Coordinating Inventory of materials (Clinker, Lime stone, Gypsum and Iron ore etc:) Monitor the refractory and insulation works for conformance with the provisions of the contract documents and the procedures manual.  Supervising/coordination refractory requirement for Kiln, Cooler, TAD and Pre heater. Inspection of Refractory Bricks condition in Kiln, Cooler TAD and Preheater and make a plan for Schedule stoppage for Change. Supervising/coordination refractory Installation of Kiln, Cooler, TAD and Pre heater in annual Stoppages.

 Conducts shift turn-over by determining plant status at the start and end of shift. Identifies abnormalities or any unresolved problems to be communicated to the next shift and situations where information should be passed on to higher levels. Determine materials requirement based on production trend and other relevant factors. Guarantee adherence to the planned production plan as per manpower and materials resources. Complete all required documentation promptly and according to procedures. Ensure that any abnormalities and unresolved problems are documented in the shift report. Conducts regularly the routine roving inspections following established checklists. Identify situations where minor repairs can be carried out by production and coordinate with the Maintenance Department. Manage stockpiling of raw materials and silo levels for cement product. Oversees packing and shipping equipment to ensure smooth operations. Obtains periodic laboratory tests results and analyze by comparing to standards and targets. Take appropriate actions. Monitors throughput, identify opportunities and decide on changes in operating parameters to optimize output. Ensures that procedures are followed for the start-up and stop of mills. Recommends proposals that would enhance production capacity and efficiency. Directs the conduct of activities relative to the inspection of various equipment’s, flow of raw materials, other production-related activities and minor corrective repairs of machineries. Supervises Mill Operators reporting within the shift. Produces according to safety plans and address any identified situations. Ensures safe working conditions for all personnel within his place and time of duty.

 Daily production report preparation and management. Complete monitoring and inspection of line-1 and line-2. A Part of Commissioning team of Line-2 and line-3. Follow up for productivity and efficiency of the unit crusher, raw mill, kiln, cooler and cement mill on 24 hours basis. Contracts and BOQS preparation of refractory material (bricks, castable, anchors and insulation boards), schedule of installation, and billing of refractory project line-2 and line-3 (6700T/D).  Contracts and BOQS preparation of external insulation (glass wool, GI sheets, nut and bolts, strips and blind revits), Schedule of installation and billing of external insulation of line-2 and line-3 (6700 T/D). To execute relevant site activities in conformance with project drawings, specifications, schedules, time estimates, procedures, quality requirement and safety standards. Review drawings as per contract drawings and project requirements. Monitor the refractory and insulation works for conformance with the provisions of the contract documents and the procedures manual.