Plant Operations Manager in Bitumen

Job Description:

The Plant Operations Manager for Bitumen EPS/XPS is responsible for the overall planning, direction, and coordination of all manufacturing operations within the facility. This includes managing production processes, ensuring product quality and safety standards, optimizing efficiency, controlling costs, and leading a diverse team. The manager will be instrumental in implementing continuous improvement initiatives and maintaining compliance with all relevant regulations.

Key Responsibilities:

• Operational Leadership:
• Oversee daily production activities, ensuring manufacturing targets for bitumen EPS/XPS insulation products are met or exceeded.
• Develop and implement operational strategies, procedures, and policies to optimize production flow, reduce waste, and improve efficiency.
• Monitor key performance indicators (KPIs) such as production volume, quality, safety incidents, and cost metrics, taking corrective actions as needed.
• Manage production schedules, resource allocation (manpower, raw materials, equipment), and inventory control to ensure seamless operations.
• Safety, Quality, and Compliance:
• Champion a strong safety culture, ensuring strict adherence to all health, safety, and environmental (HSE) regulations and company policies.
• Conduct regular safety audits, implement corrective actions for identified hazards, and lead incident investigations.
• Ensure product quality meets specified standards for Bitumen EPS/XPS, including dimensional accuracy, insulation properties, and bitumen adhesion.
• Maintain compliance with industry standards, environmental regulations, and local permits.
• Team Management & Development:
• Lead, mentor, and motivate a team of production supervisors, operators, and maintenance personnel.
• Conduct performance reviews, identify training needs, and facilitate professional development for plant staff.
• Foster a collaborative and productive work environment, promoting teamwork and continuous learning.
• Manage staffing levels, including recruitment and retention, to ensure adequate manpower for operations.
• Maintenance & Reliability:
• Oversee the preventive and predictive maintenance programs for all plant machinery and equipment specific to bitumen application, EPS/XPS extrusion, cutting, and packaging.
• Coordinate with the maintenance team to minimize downtime and ensure optimal equipment reliability.
• Manage spare parts inventory and procurement for critical machinery.
• Cost Control & Budget Management:
• Develop and manage the plant's operational budget, identifying opportunities for cost reduction without compromising quality or safety.
• Monitor raw material consumption, energy usage, and labor costs to optimize efficiency and profitability.
• Negotiate with suppliers for cost-effective procurement of raw materials and services.
• Continuous Improvement:
• Drive Lean Manufacturing, Six Sigma, and other continuous improvement initiatives to enhance productivity, quality, and cost-effectiveness.
• Analyze production data to identify bottlenecks and areas for process optimization.
• Implement new technologies and best practices relevant to bitumen coating and EPS/XPS manufacturing.
• Reporting & Communication:
• Prepare and present regular reports on plant performance, operational challenges, and improvement initiatives to senior management.
• Liaise effectively with other departments (e.g., Sales, R&D, Supply Chain) to ensure alignment and support overall business objectives.

Requirements:

• Education:
• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Industrial Engineering, Operations Management, or a related technical field.
• A Master's degree or relevant professional certifications (e.g., Lean Six Sigma Green/Black Belt) is often preferred.
• Experience:
• Minimum of 7-10 years of progressive experience in plant operations management within a manufacturing environment.
• Crucially, direct experience with polymer extrusion (EPS/XPS) and/or bitumen processing/asphalt production is highly desirable. Experience in insulation manufacturing is a significant advantage.
• Proven track record of successfully managing large teams and achieving operational excellence.
• Demonstrated experience in implementing and sustaining continuous improvement methodologies.
• Technical Skills:
• In-depth knowledge of manufacturing processes, particularly related to polymer extrusion, material handling, and coating processes.
• Understanding of bitumen chemistry and its application in insulation materials.
• Proficiency in interpreting technical drawings, P&IDs, and operational manuals.
• Strong analytical skills for data interpretation and problem-solving.
• Familiarity with Enterprise Resource Planning (ERP) systems and Manufacturing Execution Systems (MES).
• Leadership & Soft Skills:
• Exceptional leadership and team-building abilities, with a proven capacity to motivate, train, and manage diverse workforces.
• Strong communication skills (written and verbal) for effective interaction with all levels of the organization and external stakeholders.
• Excellent problem-solving and decision-making capabilities, especially under pressure.
• Results-oriented with a strong focus on safety, quality, and efficiency.
• Ability to manage multiple priorities and projects simultaneously.
• Adaptability and resilience in a fast-paced, industrial environment.
• Safety Certifications:
• Relevant safety certifications (e.g., OSHA 30, IOSH Managing Safely) are often required or highly valued.

This role is vital for ensuring the efficient and effective production of specialized insulation materials, contributing directly to the company's profitability and reputation for quality.

Job Type: Full-time

Application Question(s):

• How many years of experience do you have as a Plant Operations Manager in Bitumen, EPS/XPS Manufacturing?
• What is your expected salary in AED monthly?
• Are you okay with relocation to QATAR if all conditions fit you?
• Can you join immediately? If not, what is your notice period?