Process Improvement & PLC Systems Specialist

Job Description
Process Improvement & PLC Systems Specialist

OPERATIONS DIVISION

Job Title : MANAGER
Division : PROCESS IMPROVEMENT - PROJECTS
Department : Central Engineering and Asset Management
Primary Purpose : To lead and drive strategic process improvement initiatives and
complex projects within the aluminum manufacturing or fabrication
operations, aiming to optimize efficiency, reduce costs, enhance
quality, and foster a culture of continuous improvement. Overseeing all
electronic and control systems, including automation, instrumentation,
and control systems. Ensures the integration and optimization of
electronic systems across all projects. Advise on machine PLC
upgrade and on deciding whether to upgrade on buy new. Leading the
commissioning and start up efforts of various machines and suggest
safety and productivity improvements.

JOB DESCRIPTION
 Project Management Leadership:
1. Lead the planning and execution of complex capital projects, process
upgrades, and technology implementations related to aluminum production.
2. Manage project budgets, schedules, and resources, ensuring projects are
delivered on time and within budget.
3. Oversee project risk management and ensure compliance with safety and
environmental regulations.
4. Provide strategic guidance and mentorship to project managers and team
members.

 Assessment of Current State
1. Machine Condition Analysis: Evaluate the current condition of the casting,
wire drawing and stranding machines.
2. Process Mapping: Document the current manual operations, identifying
areas where automation can bring the most value.
3. Operational Challenges: Highlight key challenges, such as downtime,
maintenance issues, manual intervention points, and safety concerns.

 Upgrade Plan for Machines
1. Retrofit vs. Replacement: Determine which machines can be retrofitted with
modern control systems versus those that might require replacement.

2. Automation Readiness: Assess the compatibility of existing machines with
automation solutions (e.g., PLCs, sensors, data acquisition systems).
3. Prioritization: Rank machines based on their impact on production, ease of
automation, and ROI.
 Automation Strategy
1. Control System Integration: Propose integrating modern PLCs and SCADA
systems for centralized monitoring and control.
2. Sensor Implementation: Use sensors for real-time data collection on
parameters like tension, speed, vibration, temperature, and alignment.
 Digital Transformation Initiatives
1. Data Analytics: Set up systems for capturing data for predictive maintenance,
process optimization, and downtime analysis.
2. Remote Monitoring: Develop a dashboard for real-time monitoring of
machine performance, allowing remote access and control.
 Training and Skill Development
1. Staff Training: Plan training programs for operators to adapt to automated
systems, including safety protocols and basic troubleshooting.

 Technology and Innovation:
1. Stay abreast of the newest technologies and innovation within the aluminum
conductor industry.
2. Lead the implementation of new technology that will improve processes.
3. Provide a detailed cost analysis for the proposed upgrades, highlighting
expected ROI and payback periods.

 Education & Certifications:
- Diploma or Degree in Electronics / Electrical / Industrial Automation
Engineering.
- Professional training in Siemens PLCs (S5, S7), SCADA, MES.
- Additional certification in maintenance management, project management, or
Lean Six Sigma is a plus.

 Soft Skills:
- Excellent analytical and problem-solving skills.
- Strong communication and stakeholder management.
- Ability to lead cross-functional teams and manage vendors.
- Leadership experience in technical environments.