Rotary Kiln Foreman

RHI Magnesita • West Manchester Township, PA

1d • Onsite

About The Position

The Rotary Kiln Team Foreman is responsible for ensuring safe, efficient, and compliant kiln operations throughout the shift by leading safety practices, verifying critical inspections, coordinating maintenance and breakdown response, and aligning daily activities with production, quality, and regulatory requirements. The role oversees operator PM verification, cost tracking, emissions and dust‑control monitoring, supply management, and adherence to work order priorities while optimizing kiln performance through parameter adjustments and rapid response to process upsets. The Foreman drives team performance through on‑the‑job training, recordkeeping, testing, job rotation, and clear communication during shift handovers, while maintaining accurate production reporting, managing staffing and time approvals, and holding team members accountable to standards.

Requirements

• 5+ years of experience in a manufacturing environment.
• Experienced in building high‑performing teams by providing guidance, structured development, and consistent leadership presence.
• Excellent problem-solving abilities and mechanical aptitude
• In-depth understanding of safety regulations and manufacturing processes.
• Familiarity with quality control methodologies and tools, such as root cause analysis.
• Experience with process optimization, 6S/Lean practices and principles, and continuous improvement methodologies.
• Ability to work collaboratively with cross-functional teams.
• Strong written and verbal communication skills.
• Detail-oriented, proactive, and able to work effectively under pressure.
• Microsoft proficiency (Word, Outlook, Excel) and SAP.
• Demonstrates professionalism and a commitment to company values

Responsibilities

• Enforce all safety procedures, including PPE use, workplace exams, confined space documentation, LOTO sign offs, and work permits.
• Lead start of shift safety activities such as stretching and toolbox talks.
• Support incident investigations and ensure adherence to emergency procedures and company policies, including drug and alcohol testing.
• Monitor emissions, dust control, and waste handling to meet regulatory standards.
• Conduct contractor safety checks and ensure compliance during outages and daily operations.
• Align shift activities with daily production plans, maintenance schedules, and quality requirements.
• Adjust kiln operating parameters (speed, draft, ball charge, ring removal) to optimize performance and energy efficiency.
• Respond quickly to process upsets, troubleshoot equipment deviations, and maintain stable kiln operation.
• Ensure timely loading of bulk trucks and proper execution of kiln related tasks assigned by the Rotary Kiln Supervisor.
• Enter production data, notifications, and OEE information accurately.
• Coordinate breakdown responses and communicate equipment issues promptly.
• Verify completion of operator PMs and fire extinguisher PMs; assign follow up as needed.
• Perform monthly cost entries for PMs and support outage activities, including contractor oversight and refractory inspections.
• Follow work order priorities established by the Rotary Kiln Supervisor.
• Provide on the job training for operators in equipment operation, troubleshooting, and safety practices.
• Optimize performance — Adjust operating conditions based off (quality results for sinter, feed, and coal and kiln conditions) to improve efficiency, reduce energy consumption, and maintain stable kiln operations.
• Respond to process upsets — Troubleshoot equipment or process deviations quickly to minimize downtime and maintain product consistency.
• Maintain training manuals, testing documentation, and quality/safety training records.
• Administer operator tests and ensure job rotation to keep skills current.
• Ensure document control compliance by removing expired documents and verifying revision sign offs.
• Lead start of shift manpower planning, team communication, and Obeya activities.
• Facilitate effective shift handovers and follow up on unresolved issues.
• Communicate downtime events to production leadership and coordinate with HSE, HPS, Grinding, Quarry, Minerals, and Maintenance teams.
• Set a positive example and hold team members accountable for performance, attendance, and adherence to policies.
• Manage supply cabinets, order tools and Hi Vac accessories, and coordinate with Central Stores.
• Perform SAP material charge outs and support Scale House issues during off shifts.
• Approve time entries, time off requests, and ensure adequate shift coverage.
• Conduct layered process audits and support 6S responsibilities.
• Conduct hourly performance reviews and support establishing hourly goals with Rotary Kiln Supervisor and Head of Minerals Plant.
• Perform other duties as assigned by leadership.

Benefits

• $1.50 Shift Premium & $1.60 Weekend Premium
• $200 voucher for required steel toe boots with met guard (& prescription safety glasses if requested)
• Company-issued uniforms are provided and professionally laundered at no cost to employees.
• Continued growth based on skillset and capabilities. The more you can do, the more you can earn.
• Amazing benefits that start within 30 days of hire.
• 6% company match on 401k
• 3 weeks PTO (increases to 4 weeks on 4th anniversary)
• Competitively priced benefits

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: No Education Listed