Process Engineer & Production Shift Supervisor
Mombasa Cement Limited
مجموع سنوات الخبرة :15 years, 1 أشهر
Owner of processes and product quality in the clinker and cement manufacture from crushing, material handling, raw milling, kiln pyrolysis operations to finish milling. Establishes and drives plant performance indicators including raw materials, quality, energy usage, cost and overall equipment efficiency whilst ensuring plant operations are conducted in a manner that maximizes the safety of the employees and surrounding community by conforming to regulated standards and requirements.
• Exceeded production target of 5, 000 tonnes per day of clinker through establishing appropriate priorities on shift by managing, coordinating and overseeing the effective and seamless execution of all plant operations.
• Drove plant reliability through interfacing and building conducive relations with cross-functional teams (Electrical, Instrumentation, Mechanical, Quality and Safety) in order to provide rapid solutions to operational challenges.
• Spearheaded leading cross-functional teams in providing engineering support in all plants operations and in identifying improvement opportunities to optimize efficiency, production output, quality and operational costs.
• Achieved 100% availability of plants’ equipment by monitoring their operations in order to detect malfunction/ abnormal situations and trigger the necessary corrective actions by calling for repairs and follow up to completion.
• Enhanced continuity of plants’ operations by coordinating production start - up, shift change overs and shut downs including answering alarms and interruptions during respective shift as needed.
• Minimized downtime and operational costs through conducting regular process integrity inspections of +60 equipment, managing equipment failure and process upset conditions.
• Recorded and maintained an accurate and detailed account of shift activities and operations in the shift report and performed engineering analysis to reduce downtime, outages and cases of non - conformities.
• Led in incident root cause analysis and corrective action implementation for failures and non - conformities related to production losses, quality deviations, safety incidents and environmental deviations.
• Supervised and managed a team of 20+ production technicians and process attendants including training, coaching and mentoring them in order to understand the process and equipping them to detect, escalate and resolve challenges/ variances in their domain.
• Organized shift work schedule; coordinated vacations and replacements as needed; evaluated performance of production technicians and attendants in order to develop their skill including disciplinary corrective actions.
• Optimized plant performance by reviewing production, quality, operations and maintenance reports and identifying areas to drive out operational waste, reduce the cost of production, increase revenue and improve quality.
• Led continuous improvement of the processes and plant operations by keeping abreast of new and better process initiatives prevailing in the industry, introducing them in the plant and carrying out modifications.
• Oversaw safety of the workforce by ensuring compliance to safety regulations and taking the right precautionary measures e.g. conducting tool box talks, job safety & health analysis and ensuring ‘Permit to Work’ are undertaken prior to commencement of tasks, Lock Out Tag Out Try Out (LOTOTO) guidelines.
• Reduced plants’ incidents by 50% through conducting regular safety trainings with all attendants and creating awareness of hazards and behaviors.
• Maintained good housekeeping in all work stations and identified process safety threats, unsafe operations and practices and provided mitigation plans.
• Enforced environmental compliance on shift by reporting on noticeable hazards, auditing and future planning.
Created, maintained and propelled project execution (from conception to delivery) while balancing scope, budgets, resources and timelines. Identified tasks, tracked project schedules and managed risks. Performed resource forecasting, planning and management.
• Completed +50 small to medium sized projects with assigned values totaling over KES 20 million.
• Managed multiple quality projects simultaneously and consistently.
• Facilitated clear and timely communication across all internal teams and stakeholders to ensure priorities were aligned.
• Ensured all teams were properly equipped with necessary resources and completed 85% of projects on time.
• Conducted regularly inventory and research on materials to identify opportunities to reduce budget and increase revenue.
• Developed detailed work plans, project estimates, status reports, project tracking and analysis.
• Managed critical milestones throughout the projects to ensure the best customer experience.
• Demonstrated leadership skills and experience mentoring others in on-the-job training with advanced technical skills specific to assignment.
• Assisted in preparing Bills of Quantity for consultancy and construction project works.
• Oversaw project procurement management.
Identified and suggested solutions to technical problems encountered during operations which could not be readily resolved by the operations team on board by liaising with the operations manager and relevant 3rd parties such as Kenya Ports Authority (KPA), Kenya Revenue Authority (KRA) - Customs, Kenya Bureau of Standards (KEBS), National Environment Management Authority (NEMA), Empty Container Depots and Container Freight Stations (CFSs).
• Increased revenue collection on demurrage and detention charges by 50% through proactively following up with customers on collection of full equipment and return of empty equipment.
• Developed and revised standard operating procedures for operations, streamlined processes, improved communication and collaboration with cross-functional teams.
• Spearheaded equipment audits and stock taking by conducting quarterly census to identify physical location of all equipment and performed system reconciliation.
• Initiated claims for lost, damaged and unaccounted equipment with customers, claims and security teams for appropriate action.
• Reported to management on equipment stock levels and action plan.
• Created, updated and maintained an electronic document management structure in a systematic manner.
Provided support by developing and commissioning new product; improving existing processes; revising process parameters and assisting with design updates. Troubleshot hot rolling operational issues in order to improve downtime, production inefficiencies and products quality.
• Designed and commissioned 500+ roll passes and guide boxes for various steel sections (Angle lines, channels, beams, round & square bars, deformed bars and flat bars) of different sizes.
• Managed rolling mill setting; roll change activity; guide boxes setting and ensured pass alignment as per standard procedure.
• Assisted with new product development including performing product trials, drawing modifications, redesigning of mill equipment, guide boxes and roll passes.
• Coordinated the supply of raw materials (Ingots and billets) with the required chemical properties based on the established production schedule.
• Maximized productivity and optimized the utilization of manpower, resources and equipment by planning, scheduling and implementing plant operations.
• Collaborated with maintenance team on planned outages, preventive maintenance and special projects for the rolling mill to prevent delays during operating hours; eliminate bottlenecks and improve quality of the products.
• Analyzed equipment and machinery breakdowns/ malfunctions to identify root causes and resolved issues.
• Thoroughly inspected 10000+ products, quickly identifying defects and inconsistencies and followed up to have them resolved.
• Spearheaded improved methods of communication and escalating material inefficiencies and errors, reducing overall waste by 50%.
• Established a system for reporting all process and operational incidents, near misses and accidents and led investigation for root cause analysis and instigation of appropriate action.
Production of Soda Ash from Brine of Lake Natron
Kenya Certificate of Secondary Education: K.C.S.E
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