Job Description

Lead Section In-Charge – Production, Cement Grinding Unit

Position Summary

The Lead Section In-Charge – Production is responsible for overall supervision and control of the cement grinding section to achieve production targets safely, efficiently, and economically. The role involves managing grinding mills, separators, conveying systems, packing/dispatch interfaces, and associated equipment while maintaining product quality, equipment reliability, and optimum energy consumption.

Key Responsibilities

• Plan, supervise, and control day-to-day cement grinding operations in accordance with production plans and dispatch requirements.
• Achieve daily, monthly, and annual production targets while maintaining optimum mill utilization and operating efficiency.
• Monitor and control grinding mill, separator, bucket elevator, belt conveyor, air slide, fan, silo, and other associated equipment.
• Optimize mill operating parameters such as feed rate, mill ventilation, separator speed, grinding pressure, circulating load, product fineness, and residue.
• Ensure production of cement grades as per approved quality specifications and customer requirements.
• Coordinate with Quality Control/Laboratory personnel for maintaining cement fineness, setting time, strength, residue, and other relevant parameters.
• Monitor specific power consumption, mill output, grinding efficiency, and other key production KPIs and initiate corrective actions where required.
• Identify abnormal operating conditions, process deviations, and equipment problems and take timely corrective action.
• Coordinate with Maintenance, Electrical, Instrumentation, Quality Control, Stores, and Dispatch teams for smooth plant operation.
• Ensure proper startup, shutdown, changeover, and emergency operating procedures are followed.
• Supervise shift operators, technicians, and contract manpower working in the production section.
• Allocate manpower and ensure effective utilization of available resources.
• Conduct shift-wise inspection of equipment and operating areas and report abnormalities for corrective action.
• Ensure compliance with SOPs, work instructions, process parameters, and company standards.
• Maintain production logs, shift reports, equipment performance records, and other required documentation.
• Analyze production losses, downtime, quality deviations, and process interruptions and recommend improvement measures.
• Implement process optimization and continuous improvement initiatives to improve productivity and reduce operating costs.
• Support trials of new raw materials, grinding aids, process changes, and operating conditions as required.
• Ensure proper housekeeping and 5S practices within the production area.
• Enforce all safety procedures, permit-to-work requirements, PPE standards, and safe operating practices.
• Participate in risk assessments, safety inspections, incident investigations, and corrective/preventive action programs.
• Ensure that environmental requirements related to dust emissions, noise, material handling, and waste management are followed.
• Train and develop operators and junior personnel on safe and efficient operation of the grinding system.
• Coordinate with the shift/section head regarding production status, operational problems, manpower requirements, and improvement activities.

Major Equipment/Areas of Responsibility

Depending on plant configuration, responsibility may include:

• Cement grinding mills – VRM, ball mill, or roller press-based systems
• Dynamic/static separators
• Clinker, gypsum, and additive feeding systems
• Weigh feeders and dosing systems
• Bucket elevators and belt conveyors
• Cement transport and conveying systems
• Bag filters and process fans
• Cement silos and associated equipment
• Cement packing/dispatch interface
• Compressed-air and auxiliary systems
• PLC/DCS-based process control systems

Key Performance Indicators (KPIs)

• Cement production in TPD
• Mill output and utilization
• Equipment availability
• Specific power consumption, kWh/ton of cement
• Cement quality and consistency
• Product fineness/residue
• Process and equipment downtime
• Production loss and rejection
• Grinding efficiency
• Consumption of grinding aids and other process materials
• Safety performance
• Housekeeping and 5S compliance
• Manpower productivity
• Cost per tonne of cement produced

Authority and Decision-Making

• Adjust operating parameters within approved process limits to optimize production and quality.
• Stop or reduce equipment operation when unsafe or abnormal conditions are identified.
• Recommend maintenance intervention for defective or deteriorating equipment.
• Allocate shift manpower and operating responsibilities.
• Escalate major process, quality, safety, or equipment issues to the Section Head/Production Manager.

Qualifications

• Diploma/B.E./B.Tech in Mechanical, Chemical, Production, or a related engineering discipline.
• Relevant experience in cement manufacturing, preferably in cement grinding operations.
• Practical knowledge of cement grinding processes, process control, and plant equipment.
• Knowledge of DCS/PLC-based plant operation is desirable.

Experience

Typically 5–10 years of relevant experience in cement grinding operations, with demonstrated experience in supervising production operations and operating personnel.

Required Competencies

• Strong knowledge of cement grinding technology and process parameters.
• Good understanding of mill and separator operation.
• Production planning and target achievement.
• Process troubleshooting and analytical skills.
• Leadership and manpower-management capability.
• Knowledge of occupational safety and environmental requirements.
• Coordination and communication skills.
• Ability to work in shifts and handle emergency operating situations.
• Computer/DCS/ERP reporting skills.
• Continuous-improvement and problem-solving mindset.

Reporting

Reports To: Section Head / Production Manager / Plant Head, as applicable.

Supervises: Shift Operators, CCR Operators, Field Operators, Technicians, and contract manpower assigned to the grinding section.

Overall Objective

To ensure safe, reliable, cost-effective, and quality-compliant operation of the cement grinding unit, achieving production targets with optimum equipment utilization, minimum downtime, controlled power consumption, and continuous improvement in operational efficiency.