Process Improvement Specialist

Job Summary

Provide assistance to Division Operations, Technical Services, and Operations Support groups to test, analyze and improve aggregate production plant efficiencies while producing a quality product along with field application of hardware and software related to automated plant controls and data collection. Duties include:

• Working closely with other Process Improvement Specialists to identify processing bottlenecks and provide guidance for solution development across all processing segments, adjusting for productivity demands and changing field conditions

• Perform segmented focus studies to justify potential solutions both independently and with other operations support groups

• Work with Process Controls Engineers to troubleshoot, adjust, and optimize software tools for safe and efficient plant production controls

• Work with plant operators to customize and optimize use of PLC based control systems and PC graphic user interface

• Perform Automation/Historian Site Evaluations to identify potential production deficiencies related to the automation system and work with other operations support groups to implement solutions

• Troubleshoot, evaluate, and maintain effectiveness of hardware such as bin/bowl sensors, belt scales, variable frequency drives, etc.

• Learn to use the various company data sources to create custom reporting for operations managers and project-oriented field studies

• Conduct field studies to gather information that cannot be measured through digital systems

• Roughly 80% time in the field 

While the main focus of this position is supporting automation and process intelligence utilization at the operations, the position must be willing and able to assist other process improvement specialists with tasks such as:

• Perform pit/mobile equipment, screen, crusher, and fines recovery focus studies to maximize efficiencies. Identify potential production deficiencies related to the automation system and work with other operations support groups to find solutions.

• Monitoring and review of crusher testing to maximize product throughput, profile liners, and manage the cost utilization of liners

• Assist with plant studies. Conduct field studies to gather information that cannot be measured through digital systems

• Utilize software such as AggFlow, AggQC, CrusherQC, Vantagepoint, and Historian to monitor and model plants, evaluate data, and analyze potential plant changes

• Review, track and document different pit/plant setups for various modes including blending, screen media, chute flow, crusher settings, and production rates of key product

Behavioral Expectations  

• High Integrity:  Acts with unyielding integrity and honesty in business transactions, promoting company policies and holding self and other employees accountable, keeping promises and commitments.  

• Self-Motivated:  Initiates and takes action before being required to do so.  Collaborates with others to address issues that arise. 

• Business Understanding: Thorough understanding of the business purpose.  Recognizes business constraints - what is and is not possible at certain times or in certain positions.

• Responsive: Responds promptly and accurately to requests for information; coordinates appropriate follow-up.

   

Critical Competencies

• Internal Customer Focus:  Takes responsibility for internal customer relationships with operations, keeping promises and commitments.

• Communication Skills:  Communicates clearly and listens carefully in an open, candid and consistent manner.

• Production Knowledge: Understands the production plants capabilities and works to improve efficiencies of these plants while maintaining product quality.

• Leadership Skills:  Acts decisively and supports all aspects of the company to work together to accomplish objectives, vision, mission and values of Vulcan.  Trusts and allows people to do their job, holding them accountable for the full extent of their responsibilities.  Set the example for working safely.

Education, Experience, Skills Required

• Degree in Engineering or Computer Science OR 5 years mining, operating, or quality control experience in the aggregate industry 

• Experience in processing/manufacturing automation and/or aggregate production plant operation.  

Knowledge, Skills, and Abilities: 

• Possess strong initiative, motivation, assertiveness and a positive attitude.  Must sustain high ethical and moral standards;

• Safety-first attitude and willingness to communicate any concerns to peers

• Ability to inspire creativity, integrity, stewardship and loyalty with peers;

• High degree of aggregate plant and product knowledge;

• Thorough understanding of aggregate qualities, blending scenarios and plant setups to determine how proposed mine plans and plant changes could impact a plant’s ability to meet quality and state agency requirements;

• Ability to anticipate, plan and coordinate events, and proactively think through hypothetical “what if” scenarios to develop contingency plans;

• Excellent written and oral communication skills including presentation and speaking skills in group settings

• Strong analytical and mathematical skills

• Ability to work independently with minimal supervision; self-directed and motivated; highly organized

• Strong computer skills and ability to learn the operation of new software programs

Essential Functions

1. Working knowledge of automation software capabilities related to plant production controls, user interface graphics, and reporting tools 

2. Conduct plant operator Q&A to improve and tune the automation systems

3. Inspect, maintain, and provide guidance for proper hardware installation and operation

4. Coordinate and troubleshoot new system start-ups

5. Utilize Vantagepoint, Historian, and process intelligence to monitor plant efficiencies and production and monitor changes to the plants

6. Analyze data systems (web based or local) to identify, report, and monitor production optimization projects

7. Conduct field studies to verify and ‘fill in the blanks’ with digital systems data

8. Participate in and review plant studies with operations personnel 

9. Monitor crusher testing for all plants in the region and review results with operations personnel;

10. Assist operations in analysis of other production equipment as needed such as screens, crushers, wash screws, mobile equipment, etc.

11. Develop and present successful case studies and training

12. Assist Process Controls Group, Operations, and Tech Services with other functions as necessary

13. Utilize Aggflow and other simulation type programs to model and analyze plants and potential changes to plants

Other Requirements

• Use of telephone, computers, cell phones and other electronic devices is essential; 
• Travel in area of responsibility as well as a periodic need to travel by airline;
• Must have a current valid driver’s license and ability to use motorized vehicles
• Must have the ability to occasionally lift up to 75 pounds and to stand and walk for extended         periods of time; and
• Ability to work in a deadline-oriented environment that requires complex, technical information and decision-making.  Must be able to present complex information in a clear and concise manner. 
  JD Disclaimer
  Vulcan Materials Company is an equal opportunity employer.