Process & Quality Head – Cement Manufacturing
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West Bengal
Experience : 15-20 years- Job ID : MIS/26/14
Salary : As per market standards
Openings : 1
Job Description
We are looking for an experienced Head – Process & Quality to lead the process engineering and quality functions of an integrated cement manufacturing plant. The role will focus on process stability, clinker and cement quality, productivity improvement, energy optimization, manufacturing cost reduction, and compliance with applicable quality and statutory standards.
Role Overview
The Head – Process & Quality will oversee kiln, raw mill, coal mill, cement mill, packing, process engineering, and laboratory quality functions. The position requires strong expertise in cement manufacturing, pyroprocessing, grinding technology, process control, quality management, and technical improvement initiatives.
Key Responsibilities
Process Management
- Monitor and optimize kiln, raw mill, coal mill, cement mill, and packing plant operations.
- Maximize clinker and cement production while maintaining stable process conditions.
- Optimize thermal and electrical energy consumption across plant operations.
- Reduce process losses and improve overall equipment and process efficiency.
- Conduct process audits and implement corrective and preventive actions.
- Identify and implement process improvement and productivity enhancement initiatives.
Quality Management
- Ensure consistent clinker and cement quality in line with BIS, ASTM, EN, and customer specifications.
- Lead quality assurance and quality control laboratory functions.
- Monitor the quality of raw materials, fuels, clinker, gypsum, and cement.
- Establish and maintain quality control plans, testing procedures, and quality parameters.
- Lead customer complaint investigations and corrective actions.
- Ensure calibration, reliability, and compliance of laboratory equipment.
Technical & Operational Excellence
- Analyze process data and recommend measures to improve plant performance.
- Lead Root Cause Analysis (RCA) for process deviations, quality issues, and recurring problems.
- Optimize kiln operation, burning zone stability, and clinker quality.
- Improve cement grinding performance, productivity, and product fineness.
- Implement Statistical Process Control (SPC) and digital process monitoring.
- Drive benchmarking, technical best practices, and continuous improvement across plant operations.
Energy & Cost Optimization
- Reduce specific heat consumption and improve kiln thermal efficiency.
- Improve specific electrical power consumption in cement manufacturing.
- Optimize the utilization of Alternative Fuels and Raw Materials (AFR).
- Identify process opportunities to reduce overall cement manufacturing costs.
- Monitor energy performance and implement improvement initiatives.
Compliance & Quality Systems
- Ensure compliance with ISO 9001, ISO 14001, ISO 45001, and applicable quality standards.
- Support statutory inspections, customer assessments, and external audits.
- Ensure laboratory operations comply with applicable testing and quality standards.
- Maintain robust documentation and quality management systems.
Team Leadership
- Lead process engineers, CCR operators, laboratory personnel, and quality engineers.
- Coach and develop technical teams and strengthen process expertise.
- Promote a culture of data-driven decision-making, problem-solving, and continuous improvement.
- Collaborate with production, maintenance, quality, and other functions to achieve plant performance objectives.
Key Performance Indicators (KPIs)
- Kiln stability and process performance
- Clinker free lime consistency
- Specific heat consumption
- Specific power consumption
- Cement strength achievement
- Product quality compliance
- Customer complaint rate
- Process availability
- Cement mill productivity
- Alternative fuel substitution rate
- Manufacturing cost reduction
- Process improvement project implementation
Requirements
- Bachelor's degree in Chemical, Mechanical, Mineral Processing, or Cement Technology Engineering.
- Postgraduate qualification in Cement Technology or Process Engineering is desirable.
- 15–20+ years of experience in cement manufacturing.
- Minimum 5 years of experience leading process engineering and quality functions.
- Experience with integrated cement plants and modern DCS/Expert Optimizer systems.
- Strong exposure to kiln operation, pyroprocessing, grinding technology, and laboratory quality systems.
- Strong knowledge of cement manufacturing processes, kiln optimization, raw mix design, and cement grinding.
- Expertise in DCS, SPC, RCA, FMEA, Six Sigma/Lean Manufacturing, energy management, and AFR.
- Strong analytical, problem-solving, decision-making, and team leadership capabilities.
- Excellent cross-functional collaboration, communication, and influencing skills.
About the Role
This is a senior cement process and quality leadership opportunity for an experienced professional capable of combining technical process expertise with quality management and operational excellence. The ideal candidate will have extensive experience optimizing integrated cement plants, improving kiln and grinding performance, maintaining consistent product quality, reducing energy consumption, and leading technical teams.
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