1. PROCESS MANAGER
OVERALL MISSION OF THE JOB
Run the process department in accordance with the annual and the long-term plan
Participate for the functions he oversees to the Advance management cycle.
The missions that have the greatest impact are :
As part of the management team, promote safety in the plant.
Improve plant reliability and performance by optimizing the process.
Implement the process related Best Practices and standards.
Contribute to the reduction of production costs by optimising the process.
Provide the plant with a medium and long term analysis of the prospects and
prepare the basics for necessary process/environment related investments.
Make sure that the production of the raw mix, clinker and cement conforms to
quality and production demands.
Participate and contribute to professional networks in his field.
Coordinate and develop people reporting to him.
MAIN ACTIVITIES / RESPONSIBILITIES
PROCESS
He or she is responsible for improving the performance of the plant's workshops in the
short, medium and long term. To do this, he or she must :
- Monitor the process performance of the entire plant on a day to day basis and
define corrective actions together with maintenance and production.
- Define process optimisation actions together with quality, production and
maintenance; monitor the actions and the results.
- Organize on a daily basis process inspections and review of performance.
- Identify and conduct studies, tests and measurements within the Process
department in order to improve performance.
- Define the day to day set points.
- Ensure correctness of sensors.
- Ensure the quality of process data reported.
- Define an audit plan and supervise the audits to detect irregularities and find
potential improvements.
- Contribute to fuel cost optimization (optimization of lowest fuel cost) by ensuring
(optimising) process condition which allows a maximum utilisation of alternative
fuel and raw materials.
- Ensure progress in control loop optimisation and high-level automation (LUCIE).
- Ensure existence and correctness of procedures.
- Ensure that audits and studies are documented and shared.
- Forster the process awareness within all departments in the plant.
- Promote exchanges between the Processes and Production departments.
- Participation in the plant managers network.
- Coordinate actions with the Technical Centre.
Job description Process Manager 1/6
2. ENVIRONMENT
Depending on the plant organisation :
- Define together with the Environmental manager the process conditions which
allows the plant to comply current and future with all environmental regulations.
- Ensure together with production that process is operated in a way to minimise
emission.
QUARRY : RAW MIX PREPARATION
He or she is responsible (together with the quarry manager) for the optimisation of the
raw mix logic to ensure a raw mix at the desired composition with a minimum of
variations.
Ensure that there is a regular communication between the quarry, process and quality for
adjusting the raw mix to the problems of burning.
MANAGEMENT
- Promote exchanges between his or her own departments and the other
departments in the plant.
- Promote the use of Lafarge information and knowledge tools (product platform,
Best Practices, Vade-Mecum, Les Cas, Easi, Team workspace, Sametime, etc..).
- Make the different departments teams aware of the environment aspects.
- Run information meetings and make his or her teams aware of safety matters and
check that safety regulations are respected.
PEOPLE DEVELOPMENT
- Induct new recruits, monitor the development of potentials, propose training
schemes for his or her teams in order to optimise their skills.
- Build and facilitate training courses inside and outside the plant.
PERFORMANCE CRITERIA
- Having a stable process at lowest possible cost.
- Quality of reporting.
- Application of best practices and use of data bases.
- Respect of procedures.
CONTEXT / STAKES
This job has currently a variable profile depending on the plants:
- In a complex plant the Process Manager reports to the plant manager.
- If a plant is defined as “standard” regarding process, the function of the process
and quality manager is combined in the position of a “Optimisation manager” in
this case the job description of the two positions have to be combined. The
Optimisation manager is reporting to the plant manager.
- In case of simple plants regarding the process, the production manager might take
over also the function of a process manager, there will still be a quality manager
reporting directly to the plant manager.
The responsibility of the Quarry is normally in production. In this case the Quarry
manager and the Process Manager have a shared responsibility for the raw mix quality.
Job description Process Manager 2/6
3. PROFILE OF NECESSARY COMPENTENCIES / SKILLS
Languages
English
Level of Education and experience required (TBD locally)
Technical expertise
o Level III in process in a complex plant, otherwise level II)
Knowledge required
- In-depth knowledge of the cement making process,
- General knowledge of physics, chemistry, science of heat and computing.
- Knowledge of the chemical parameters that affect the quality of cement.
- General knowledge of process control tools.
- Knowledge of environmental standards.
- Have an overview of the latest innovations in the cement industry
Personal skills
- Ability to work in a cross-disciplinary way.
- Inquisitive and creative.
- Results orientation.
- Innovative.
- Autonomous.
- Leadership capacity.
- Coaching and teaching abilities.
- Ability to run teams and workgroups.
- Communication
Job description Process Manager 3/6
4. PROCESS ENGINEER
OVERALL MISSION
Within the framework of the plant’s production objectives and methods and of the
quality objectives, his missions are:
Study and implement systems/tools/procedures to optimise the production
process. Lead the continues performance optimisation team
This is achieved through involvement in projects or problem solving with the
assistance of a more experienced engineer
MAIN ACTIVITIES / RESPONSIBILITIES
OPERATIONAL ROLE:
- Address production / process bottlenecks for a better output or a greater stability.
- Define instructions concerning process key parameters.
- Define production conditions for new or modified installations under supervision of
the optimisation manager or a senior process engineer.
- Conduct production process studies and audits which he deems necessary or
which are requested by the line management, with the possible assistance of
experts from the technical centre or the plant optimisation manager.
- Regularly monitor the parameters relating to plant operation.
- Liaise with the technical management for process issues and take part in the
plant development projects.
- Inform and trains operational staff.
PLANNING:
- Perform the required works within a well-defined work planning.
- Sequential intervention.
COMMUNICATION:
- Prepare written and oral reports on the work undertaken in a clear and concise
manner.
PERFORMANCE CRITERIA
Relevance of key parameters used to monitor production processes as well as
process data
Relevance and adequacy of technical surveys performed on the process (heat
balance, inspection ...)
Relevance of his recommendations concerning the modifications to be made on
various control parameters or on the process
Respect of environmental constraints
Good relations with the Technical Management relating on process matters
Quality of information and training to ensure good process control
Job description Process Manager 4/6
5. PROFILE OF NECESSARY COMPETENCIES / SKILLS
Educational Background & Experience
Degree in chemical engineering or in general engineering with process
engineering as the main subject with 1 to 3 years’ experience depending on
the size and challenges of the position
Good knowledge of the physico-chemical products, of relevant parameters
and standards applicable to cement manufacturing
Good knowledge of statistical process control methods and experimental
design
Good knowledge of project management methods
Technical skills (Process stage I)
Perform the measurements of a basic process: gas flow / temperature / gas
analysis /
Organise and perform an audit limited to one area of a plant: gas / thermal/
material balance of a kiln or a mill based on a pre-established model
Write a preliminary audit report under the supervision of a senior process
engineer
Control the process by using traditional process control tools: Calculation of
raw feed, QMC,...
Tune a control loop, establish a correctogram
Understand the strategy of an expert system (LUCIE)
Leadership & Behavioural Skills:
Vision and purpose:
Intellectual curiosity and strategic thinking
Leading people:
Communication skills
Teaching ability
Listening skills
Team spirit
Driving for results:
Eagerness to learn
Analytical skills
Objective focus
Rigour
Customer focus:
Listening skills
Leading change:
Adapting to change and creativity
Integrity and value:
Courage and integrity
Intellectual humility
Job description Process Manager 5/6
