Provide technical leadership to the departmentFacilitate and improve safety management systems. - Lead RCA and incident investigations, identifying corrective actions to prevent re-occurrence.Provide technical expertise and process understanding to the production and project teams.Review technology changes to ensure continued safe operations and is fit for purpose. - Gatekeeper of the management of change system process within the department.Co-ordination of the department improvement activities.Identify areas of potential process improvement and formulate plans for realising the benefits.Alarm and Inhibit Management.

Accountable for all Health (monitoring), Safety (incident report sign off) & Environmental (compliance) activities.Implementation of lean temple foundation stones (Information centres, 5S, Quick changeovers, standardised work) into production areas.The unloading and movement of alumina (& coke) from ship via train to site (350kT / year), through the dry scrubbing system into the electrolysis cells.The design, build, turnaround and start-up of end of life electrolysis cells (£3m / year).Compliance to environmental agency (EA) regulations for both fugitive emissions (HF gas) and particulate emissions (dust / containment issues).Management of a team of 3 process engineers, 39 operators/ welders/ repairmen, and approximately 24 full time contractors; including reviews of direct reports every 6 months.Exchange technical information as part of global technology networks for pot-lining and dry gas scrubbing.Responsible for production KPI’s and budget targets for the 3 departments under my leadership.

Responsible for innovation and project management within the cell rooms. Pushing forward process and energy efficiency, as well as delivering cost savings to the business.Examples of project workLed my production team to re-map a production process to indentify bottlenecks, propose re-designs, and then cost out solutions to support a structure approach to production increases.Key player in restarting 2 production lines. Adapting new industrial techniques to a unique technology to re-energise in record time and return pot line to full production.Re-designed an electrical connection to lower the external voltage drop on an Al-electrolysis cell and then implemented a system of work to minimise the downtime to production (saving +£1M / year in power costs).After a period of research and working with the pot line welding team, introduced a new technique of magnetic shielding for improved welding quality at high amperage.Managed the programming, implementation and training of a new process control system to modernise and increase production efficiencies.Received an internal “Bravo” award for working within a multi-disciplined team to reduce production downtime, using Continuous Improvement tools to focus group activities.Leading continuous improvement projects to increase production & reduce environmental impact; using Define, Measure, Analyse, Improve, Control gate reviews to help define project timelines.

Responsible for a team of 2 process engineers, with 3 technicans, + 10 control men (measurement team).Accountable for the performance of 2 reduction cell lines vs plan:Calculating heat and mass balances to maximise process efficiencies. Optimisation of key control parameters to support increases in production.Recognised for gaining vast practical and theoretical knowledge of aluminium electrolysis and process control. Problem solving (SPC) and providing solutions to day-day production issues.Streamlining technical processes (control algorithms, production reports) / information streams (web displays / scada) to provide faster reaction times.Analysis of mechanical failures with the aim of maximising production uptime.Pre-empting changes in raw material quality to maintain process efficiencies.5 Year Planning ahead to specify raw material scheduling and plant output.Recruitment and training of process engineers / technicians.

Responsible for understanding the electrolysis process, and running process trials using statistical analysis to increase process efficiency.