Plant Operations Manager

Job description:

Role Summary

The Plant Operations Manager will oversee end-to-end operations of  lead and aluminum recycling and smelting facility. The role involves managing production efficiency, maintaining quality standards, ensuring safety compliance, and optimizing plant performance. The ideal candidate will have hands-on experience in non-ferrous metal processing (lead/aluminum/copper), excellent technical knowledge, and proven leadership in managing production teams in Africa or similar environments.

Key Responsibilities

• Production Management:
• Plan, coordinate, and supervise all plant operations for lead and aluminum alloying and smelting.
• Ensure adherence to daily/weekly/monthly production targets and yield efficiency.
• Monitor furnace operations, melting efficiency, and alloy composition quality.

Technical Oversight:

• Manage all technical aspects of the smelting process, including temperature control, feedstock preparation, and alloying specifications.
• Optimize process parameters for energy efficiency and product quality.
• Troubleshoot production and equipment-related issues promptly.

Maintenance & Equipment:

• Develop preventive maintenance schedules for furnaces, mixers, molds, and other key plant machinery.
• Coordinate with technicians for timely repairs and spare parts management.
• Maintain equipment uptime of >95%.

Quality & Compliance:

• Maintain quality standards for lead and aluminum alloys as per export and client specifications.
• Implement EHS (Environment, Health, and Safety) best practices.
• Ensure compliance with ZEMA and local regulatory guidelines.

People Management:

• Supervise and train production staff and technicians.
• Maintain discipline, morale, and efficiency on the shop floor.
• Foster a safety-first and performance-driven culture.

Inventory & Procurement:

• Oversee input material (scrap, ingots, fluxes, fuel) management.
• Provide support in scrap procurement, identification and segregation.
• Monitor consumption, wastage, and yield variance.
• Coordinate with procurement and logistics for material supply.

Reporting & Coordination:

• Prepare periodic production and maintenance reports.
• Coordinate with the finance and operations team for cost tracking and budgeting.
• Support senior management in expansion and R&D projects.

Key Skills and Competencies

• Strong understanding of lead and aluminum smelting/alloying processes
• Excellent knowledge of furnace operations, metal refining, and quality control
• Proven track record in plant optimization, production efficiency, and EHS compliance
• Hands-on leadership and team management ability
• Strong problem-solving, analytical, and communication skills
• Comfortable working in an African or frontier-market industrial setup

Qualifications & Experience

Education: Diploma/Degree in Metallurgical, Mechanical, or Chemical Engineering. Experience: Minimum 7-10 years in non-ferrous metal production (lead, aluminum, or zinc preferred)

Preferred Background: Experience in recycling, smelting, or foundry operations. Languages: English (required), Hindi (preferred for communication with local team)

Other: Must be willing to relocate full-time to Zambia.