Manager Production (Integrated Cement Plant)

Sarthee Consultancy; Surat; On-site; INR 1,200,000 - 2,400,000; Full time

Job summary

Sarthee Consultancy seeks a seasoned Cement Plant Operations specialist to drive process excellence across raw material handling, kiln, and cement grinding. You will optimize heat and power usage, coordinate with Mines, Maintenance, and QC teams, and ensure reliable plant performance while achieving production targets.

The role requires deep process knowledge, experience with VRM/Ball Mills, and familiarity with ISO standards and quality systems.

Qualifications

• BSC Chemistry or BE Chemical degree is required.
• Deep knowledge of cement production processes and operating practices.
• Experience with VRM and Ball Mill operation and optimization.
• Proficiency in heat and mass balance calculations.
• Knowledge of kiln pyro-processing & clinkerization chemistry.
• Familiar with refractory selection, installation, and performance monitoring.
• Experience with grinding media optimization and dust collection systems.
• Understanding of alternative fuels and TSR implementation.
• Experience with QCX / Laboratory systems and DCS/PLC based control.
• Knowledge of cement quality standards and ISO systems.
• Experience with KPI monitoring and MIS/ERP tools.

Responsibilities

• Coordinate cross-functionally with Mines, Maintenance (Mechanical + E&I), Quality Control, Purchase & Stores, and Finance.
• Demonstrate track record in reducing heat and power consumption and improving kiln availability and output.
• Prepare budgets and optimize costs while meeting production targets.
• Ensure daily, monthly and annual production targets for limestone crushing, Raw Mill, Kiln & Pyro section, and cement grinding.

Skills

Raw mix design

Heat & mass balance

Kiln pyro-processing

Clinkerization chemistry

VRM operation

Ball mill operation

Coal mill optimization

Clinker cooler efficiency

Refractory selection

Grinding media optimization

Dust collectors

Alternative fuels

QCX / Laboratory systems

DCS/PLC process control

Cement quality standards

ISO 9001 / ISO 14001 / ISO 45001

Education

BSC Chemistry

BE Chemical

Job description

Education

• BSC Chemistry or BE Chemical

Technical & Process Expertise

• Deep knowledge of:
  • Raw Mix design & proportioning
  • Heat & Mass Balance calculations
  • Kiln pyro-processing & clinkerization chemistry
  • VRM and Ball Mill operation & optimization
  • Coal mill operation and fuel optimization
  • Clinker cooler efficiency improvement
• Strong understanding of:
  • Refractory selection, installation & performance monitoring
  • Grinding media optimization
  • Dust collectors, ESPs & Bag Filters
  • Alternative fuels & thermal substitution rate (TSR)
• Working knowledge of:
  • QCX / Laboratory systems
  • DCS/PLC based process control systems
  • Cement quality standards & statutory norms
  • ISO 9001 / ISO 14001 / ISO 45001 systems

Operational & Leadership Capabilities

• Strong cross-functional coordination with:
  • Mines
  • Maintenance (Mechanical + E&I)
  • Quality Control
  • Purchase & Stores
  • Finance
• Proven track record of:
  • Reducing Heat Consumption (kCal/kg clinker)
  • Reducing Power Consumption (kWh/ton cement)
  • Increasing Kiln availability & output
• Budget preparation and cost optimization skills.
• Strong MIS, ERP and KPI monitoring capability.

Production Planning & Execution

• Ensure daily, monthly & annual production targets for:
  • Limestone crushing
  • Raw Mill
  • Kiln & Pyro section
  • Cement grinding
• Optimize kiln feed chemistry and ensure stable operation.
• Maintain clinker factor and cement blending targets.
• Coordinate closely with Mines team for raw material availability and quality alignment.
• Ensure plant runs at optimum rated capacity with maximum reliability.