Hot Mill Operations Manager

SUMMARY:
Our client in Saudi Arabia is looking for Hot Mill Operations Manager to join their operations.  This position reports directly to the Operations Director. Builds rapport and establishes regular contact with maintenance, engineering, quality, finance, and other units in MRC. Has regular conversations and periodic meeting with the Operations Director. Continuous contact with area subordinates, maintaining an open and honest relationship to ensure a team orientated and “Continuous improvement” work environment which will result in a high performing area.

POSITION INFO:
Overall Job Purpose

• This position is responsible for the management of entire operations in Hot Mill for product lines and achieving all production requirements, product quality requirements, on time delivery, all at budgeted levels. 
• These objectives are achieved in part by coordinating with Engineering, Maintenance, Quality, and other Rolling departments. 
• Responsible to supervise all the people utilized and control operational processes of Scalper, Pre-heat furnace, Hot Reversing, and Hot Continuous Mill and achieve production targets, and deliver results through; Lean Manufacturing techniques and philosophies, 5S, TPM, Six Sigma and problem solving. 
• Promote EHS policy, implement the EHS management system and ensure continual improvement of EHS performance in day-to-day operations. This includes compliance to all Environment, Health, and Safety Policies and Procedures. 
• Oversee all operational activities and housekeeping efforts in the Hot Mill to ensure employee and equipment safety. 
• Maintain an ongoing knowledge of manufacturing processes, operations, and quality standards to help ensure the utilization of the best production methods and meeting of quality specifications. 
• Ensure training and development of all operating personnel to meet the ISO/IATF standards. 

• Provide leadership to assigned resources to ensure that environment, health, and safety are the number one priority of the business.
• Manage assigned resources in compliance with EHS policies to assure that environment, health, and safety are fully complied with.
• Lead and conduct key safety initiatives such as employee safety meetings and “toolbox” discussions, risk assessments, EHS audits, and environmental compliance monitoring, etc. Participate in / lead safety incidents investigations.
• Monitor and improve processes, procedures, and equipment to reduce or eliminate safety hazards and risks with a goal of achieving a zero injury.
• Accountable for ensuring department personnel follow safe standard operating procedures such that processes remain stable and product quality consistently meets or exceeds customer requirements.
• Maintain awareness of plant, corporate and government safety and health regulations and policies and initiate department action to ensure compliance with these regulations.
• Coordinate special safety initiatives and supports safe work methods.

• Contribute to defining both short-term and long-term objectives in output, quality, safety, and compliance.
• Analyse, recommend improvements, efficiently organize, and manage the direction of work teams and departmental processes for the achievement of the production targets.
• Bring hot rolling mills up to speed augmenting the functions of roll drives for higher throughput.
• Optimize performance and operational efficiency with the mechanical and hydraulic solutions.
• Fine-tune process models and networks to produce more accurately than ever before and use automation solutions to maximize Hot Mill plant’s end-to-end consistency, reliability, and security.
• Achieve highest level of productivity through the seamless integration of technology, mechanics, automation, and electrical engineering.
• Implement planning/scheduling for Hot Mill area according to the MRC standard to ensure ‘on time’ delivery to internal customer-Cold Mill.

• Ensure fast and flexible production processes that produce higher yield through reduced cropping, trimming and off-length losses to meet the customer specifications and demand.
• Minimize scrap from trimmed edges to help you achieve unrivalled cropping and width optimization.
• Aim at helping the plant achieve top performance throughout its entire life cycle.
• Work with central maintenance to customize preventive and predictive strategies and minimize unplanned downtime and reduce the costs on maintenance, spare parts and personnel.
• Maintain defined level of inventory in the HM area to achieve higher rate of productivity and quality as per the standards.

• Develop, maintain, and execute SOP for appropriate process in Hot Mill Area based on industry best practices for Can & Auto products.
• Implement visual management.
• Ensure and improve consistent product quality according to the defined parameters for quality and productivity.
• Achieve highest product quality using technologies, automatic profile, and flatness control.
• Participate in the plant wide non-conforming product system as part of the ISO/IATF management system, reporting necessary information and monitoring for trends.
• Provide support to the Quality Systems Manager in the plant’s ISO 9001 program and assist in efforts to retain certification to the IATF 16949 standard.

• Attend the daily management meeting and review all internal rejections in detail.
• Provide leadership, feedback and coaching to process/production people and other assigned personnel on operating processes.
• Lead and investigate the root cause of internal rejections, recommend corrective action, and assist in the implementation of process changes.
• Receive, evaluate, and track corrective actions in response to major internal rejections and corrective actions triggered by major customer complaints or at the customer’s request.
• Prepare and distribute reports, graphs and analysis of both Internal Rejections and Customer Rejections. Support the effort to provide information for updating production KPI’s.
• Provide support to process engineers and customers for assigned accounts.
• Develop and implement Competency mapping to find out the skill-gap and provide training & development as needed.
• Maintain compliance with all Company''s and governmental regulations.
• Maintain compliance with all safety standards. 
• Ensure these skills are evaluated at appropriate intervals and developmental plan(s) established.

• Develop and Work with central maintenance to customize preventive and predictive strategies and minimize unplanned downtime and reduce the costs on maintenance, spare parts, and personnel.
• Work closely with our Production, Maintenance, and Engineering Teams to investigate and eliminate all quality, reliability, and process concerns.
• Focus on TPM and REX maintenance process to help achieve targets.  
• Prepare budgets and achieve production within cost.
• Contributes to team efforts by accomplishing related results.

• Responsible for the performance and development of the Hot Mill team.
• Prepares action plans by individuals as well as by team for effective operations and prospects.
• Initiate and coordinate the development of action plans to innovate new operational process.
• Conduct one-on-one review with the concerned production and process personnel to build more effective communications, to understand the on-going process and provide insights for the improvement of overall performance.
• Control expenses to meet budget guidelines.
• Deliver communications from leadership using common risk management language.
• Create a culture of constructive challenge.
• Reinforce behavioural, ethical and compliance standards.

• Identifies and develops high potential employees to increase speed and enhance human productivity with quality and quantity consciousness and flexible and easily adaptable structure to ensure consistency and reliability in plant operations.
• Enhances Finishing operations by increasing employees’ technical competency and developing talent pool to achieve highest level of individual productivity and a long-term commitment.
• Leads the interface with all government agencies and departments, domestic and international, relating to the company''s readiness to technical development matters.
• Foster a culture of agility through ongoing organizational communications and education.

• Authorised to use the resources of the operating area to maintain the smooth operation of the process and fulfil duties. 
• Follows work methods as prescribed by the RM management. Supervises all personnel in the area but is also expected to lead by example. 
• Keeps Operation Management active informed on progress in his area. This role is a key operations role which spans a very wide range of responsibilities and is extremely demanding of both the time and effort of the person performing it.

• Bachelor’s Degree in engineering (Mechanical/ Electrical/ Electronics/ Instrumentation).
• Master’s Degree in Engineering with Lean Six Sigma Certification is a plus.

• 15+ years of demonstrable experience in operations of manufacturing industry (Preferably Rolling Mill).
• Minimum 5 years impressive, demonstrable track record and skills/experience gained within a similar position(s), at a similar level.
• Full knowledge and demonstrated use of Quality tools.
• Expertise in Value Stream and Cause Mapping, Visual Management, etc.
• Proven leadership and ability to drive operations teams.
• Strong understanding of customer and market dynamics and requirements.
• Willingness to travel and work in a global team of professionals.
• Experience in working in multiple businesses.
• International experience desirable.

• Strong leadership skills and experience.
• Credible and confident communicator (written and verbal) at all levels.
• First class presentation skills.
• Gravitas, with the ability to build strong teams and team spirit to enhance productivity.
• Expert negotiating and influencing skills.
• Innovative with entrepreneurial flair.
• Proven strategic aptitude and ability.
• Ability to influence at a senior level, both internally and externally.
• Tenacious and results driven with sound business judgement.
• Passionate about achieving high levels of excellence.
• Highly energised and motivated with a high level of commitment.
• Ability to work collaboratively with others to provide a high-quality service.
• Numerate with strong analytical and problem-solving ability.
• Excellent project management skills.
• Hands-on approach, with a ‘can-do’ attitude.
• Ability to prioritise, demonstrating first class organisational skills and time management skills.
• Excellent attention to detail, with the ability to work accurately in a busy & demanding environment.
• Self-motivated, with the ability to work proactively using own initiative.

• Must be able to demonstrate a broad operations and maintenance knowledge and expertise covering conduct of operational process and regulatory matters.
• Practical and commercial approach to problem solving and ability to position products with accurate quality and customer specification with minimum rejection.
• An inspiring passion for excellence. The incumbent will be required to create and inspire/drive rolling mill operation analytics and improvement mind-sets and behaviours across all levels of the organization.
• Performance and results driven – both personally and for the organization with ability to work through obstacles and is willing to put in extra hours when needed.

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