Process Improvement Specialist

Vulcan Materials Company•Piedmont, SC

About The Position

The Process Improvement Specialist supports Division Operations, Technical Services, and Operations Support groups in testing, analyzing, and improving aggregate production plant efficiencies while maintaining product quality. The role also provides field application support for hardware and software related to automated plant controls and data collection. Approximately 80% of the work is in the field. The position primarily supports automation and process intelligence at operations, while also assisting with broader process improvement work, including plant and equipment studies, crusher testing, production analysis, and evaluation of pit and plant configurations. The specialist uses company data sources and software to monitor and model plants, analyze production data, identify deficiencies and opportunities, and develop and present case studies and training. The role involves collaboration with plant operators, Process Controls Engineers, operations personnel, and other support groups, as well as travel within the area of responsibility and occasional airline travel.

Requirements

A degree in Engineering or Computer Science, or five years of mining, operating, or quality control experience in the aggregate industry.
Experience in processing or manufacturing automation and/or aggregate production plant operation.
Working knowledge of automation software capabilities related to plant production controls, user-interface graphics, and reporting tools.
Strong initiative, motivation, assertiveness, and a positive attitude; ability to maintain high ethical and moral standards.
Safety-first attitude and willingness to communicate concerns to peers.
High degree of aggregate plant and product knowledge.
Thorough understanding of aggregate qualities, blending scenarios, and plant setups to assess how mine plans and plant changes could affect product quality and state agency requirements.
Ability to anticipate, plan, and coordinate events and develop contingency plans for hypothetical scenarios.
Excellent written and oral communication skills, including presentation and group-speaking skills.
Strong analytical and mathematical skills.
Ability to work independently with minimal supervision; self-directed, motivated, and highly organized.
Strong computer skills and ability to learn new software programs.
Ability to work in a deadline-oriented environment involving complex technical information and decision-making, and to present complex information clearly and concisely.
Ability to occasionally lift up to 75 pounds and to stand and walk for extended periods.
Current valid driver’s license and ability to use motorized vehicles.
Ability to use a telephone, computers, cell phones, and other electronic devices.

Responsibilities

Work with other Process Improvement Specialists to identify processing bottlenecks and guide solution development across processing segments, adjusting for productivity demands and changing field conditions.
Perform segmented focus studies independently and with operations support groups to justify potential solutions.
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 PLC-based control systems and PC graphical user interfaces.
Conduct Automation/Historian Site Evaluations, identify production deficiencies related to automation systems, and work with operations support groups to implement solutions.
Troubleshoot, evaluate, and maintain the effectiveness of hardware such as bin and bowl sensors, belt scales, and variable frequency drives.
Learn and use 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.
Perform pit and mobile equipment, screen, crusher, and fines recovery focus studies to maximize efficiencies.
Monitor and review crusher testing to maximize product throughput, profile liners, and manage liner costs.
Assist with plant studies and gather field information that cannot be measured through digital systems.
Use AggFlow, AggQC, CrusherQC, Vantagepoint, and Historian to monitor and model plants, evaluate data, and analyze potential plant changes.
Review, track, and document pit and plant setups for blending, screen media, chute flow, crusher settings, and production rates of key products.
Conduct plant-operator Q&A to improve and tune automation systems.
Inspect and maintain hardware and provide guidance for proper installation and operation.
Coordinate and troubleshoot new system start-ups.
Use Vantagepoint, Historian, and process intelligence to monitor plant efficiencies, production, and plant changes.
Analyze web-based or local data systems to identify, report, and monitor production optimization projects.
Participate in and review plant studies with operations personnel.
Monitor crusher testing for all plants in the region and review results with operations personnel.
Assist operations in analyzing other production equipment as needed, including screens, crushers, wash screws, and mobile equipment.
Develop and present successful case studies and training.
Assist the Process Controls Group, Operations, and Technical Services with other functions as necessary.
Use AggFlow and other simulation programs to model and analyze plants and potential plant changes.
Travel within the area of responsibility and periodically by airline.
Use a current valid driver’s license to operate motorized vehicles as needed.