About the JobRole Summary:Provides technical expertise and process engineering support across cement manufacturing operations, ensuring safe, stable and efficient plant performance. Accountable for analyzing process performance, identifying operational constraints and driving continuous improvement across production systems. The position translates process data and engineering principles into practical improvements that enhance production efficiency, product quality, energy performance and operational reliability.
Purpose:Optimize cement manufacturing processes through disciplined process analysis, technical problem solving and continuous improvement. The role supports safe operations, production stability, cost efficiency, product quality and sustainable plant performance.
Key Accountabilities:- Monitor and optimize cement manufacturing processes including crushing, raw grinding, pyroprocessing, clinker cooling, finish grinding and material handling systems.
- Analyze operating data, process trends and key performance indicators to identify process constraints, efficiency losses and improvement opportunities.
- Provide technical support to production teams in troubleshooting process instability, production losses and operational challenges.
- Drive optimization of kiln, preheater, calciner, cooler and grinding systems to improve throughput, stability, fuel efficiency and product quality.
- Conduct process audits, heat and mass balances, equipment performance evaluations and technical studies.
- Identify and implement opportunities to reduce specific heat consumption, electrical consumption and other variable production costs.
- Lead root cause analysis of recurring process issues and develop sustainable corrective actions.
- Partner closely with production, maintenance, reliability and quality teams to improve overall plant performance.
- Support process control improvements including operating parameters, control strategies, instrumentation and automation initiatives.
- Support major maintenance shutdowns, kiln outages, commissioning activities and plant improvement projects.
- Participate in capital projects and equipment upgrades by providing process engineering expertise, technical analysis and operational support.
- Develop and maintain process documentation, operating standards, technical reports and performance tracking tools.
- Provide technical guidance and training to operators and production personnel on process fundamentals and best operating practices.
- Support environmental and sustainability initiatives through improved process efficiency, energy utilization and emissions performance.
- Embed UNA Culture values through collaboration, technical discipline, continuous improvement and a strong field presence across plant operations.
Knowledge:- Strong understanding of cement manufacturing processes including raw material preparation, grinding, pyroprocessing, clinker cooling and finish grinding.
- Knowledge of process engineering principles including heat and mass balances, combustion, material flow, grinding efficiency and process control.
- Understanding of cement plant equipment including kilns, preheaters, calciners, coolers, mills, separators, crushers, conveyors and material handling systems.
- Knowledge of process control systems, instrumentation, PLC/DCS environments and plant historian data.
- Strong understanding of production performance indicators including throughput, specific heat consumption, electrical consumption, equipment efficiency and process stability.
- Knowledge of continuous improvement, root cause analysis and structured problem solving methodologies.
- Understanding of safety and environmental requirements applicable to heavy industrial manufacturing operations in the United States.
Problem Solving:- Resolves complex process and production challenges with direct impact on plant throughput, quality, energy efficiency and operational performance.
- Diagnoses process instability and performance losses through structured analysis of operating data and field conditions.
- Identifies root causes of recurring production issues and develops practical, sustainable corrective actions.
- Balances production targets with process stability, equipment limitations, product quality and operating cost.
- Anticipates process risks and implements preventive actions to reduce production losses and operational disruption.
- Navigates operational complexity and uncertainty using engineering judgment, data analysis and disciplined decision making.
Interactions and Influence:- Daily interaction with plant leadership, production supervisors, control room operators and operational teams.
- Strong collaboration with maintenance, reliability, quality, environmental and engineering functions.
- Works directly with operators and technical personnel to troubleshoot plant performance and implement process improvements.
- Engagement with equipment manufacturers, engineering firms, contractors and specialized technical service providers.
- Communicates process performance, technical findings and improvement recommendations clearly to operational and leadership audiences.
- Influences operating practices and drives alignment around process optimization and continuous improvement initiatives.
Impact:Direct: Process stability, production efficiency, throughput, product quality, energy consumption and operational performance across the facility.
Indirect: Plant reliability, manufacturing cost, environmental performance, asset sustainability and long-term operational capability.
Experience and Education:- Bachelor's degree in Chemical Engineering, Mechanical Engineering, Process Engineering or related engineering field.
- Minimum three years of process engineering, production engineering or manufacturing experience within heavy industrial or continuous-process environments preferred.
- Experience in cement manufacturing required.
- Experience with kiln systems, grinding systems, process optimization, process control or other cement manufacturing operations preferred.
- Demonstrated experience using operating data and engineering analysis to identify and implement process improvements.
- Experience supporting capital projects, commissioning, shutdowns or major plant improvement initiatives preferred.
Success Profile:- Strong technical and analytical capability with a practical approach to plant problem solving.
- Hands-on engineer who maintains a strong field presence and works effectively with operators and technical teams.
- Structured problem solver capable of translating complex process data into practical operational improvements.
- Curious and proactive with a strong continuous improvement mindset.
- Comfortable challenging existing processes and identifying better ways of operating.
- Resilient and calm under pressure within demanding industrial environments.
- Builds credibility across production, maintenance and technical functions through collaboration and technical expertise.
- Acts with integrity and models the UNA Culture.
