Process Plant Operations Manager

Hiring for a the following role to be based at Lusaka, Zambia for a Leading Recycling plant

Location - Lusaka, Zambia, ON SITE

Job Title: Operations Manager Lead Acid Battery Recycling Plant

Job Summary

The Operations Manager will oversee end-to-end plant operations at the lead-acid battery recycling facility specializing in wet battery processing. The role is responsible for ensuring safe, efficient, and compliant recovery of lead, lead oxide, and other by-products while achieving production targets, operational efficiency, cost optimization, and environmental compliance. The position involves leadership of production, maintenance, safety, and operational teams to ensure smooth and sustainable plant performance.

Key Responsibilities

1. Plant Operations Management

Lead and manage overall plant operations including battery feedstock handling, crushing, separation, smelting, refining, and casting processes.

Develop operational strategies to achieve production throughput, efficiency, and quality targets.

Monitor daily plant performance and implement corrective actions to minimize downtime.

Ensure optimal utilization of manpower, machinery, and resources.

2. Production Planning & Process Optimization

Establish daily, weekly, and monthly operational plans aligned with business objectives.

Drive continuous process improvements to enhance recovery yield, productivity, and energy efficiency.

Monitor key operational parameters and ensure adherence to standard operating procedures.

Implement best practices for operational excellence and process stability.

3. Safety, Health & Environmental (HSE) Compliance

Ensure strict adherence to safety standards in handling lead, sulfuric acid, and hazardous materials.

Maintain compliance with environmental regulations related to emissions, wastewater treatment, and hazardous waste disposal.

Lead safety audits, risk assessments, incident investigations, and emergency preparedness programs.

Promote a strong safety culture across plant operations.

4. Maintenance & Asset Management

Oversee preventive and breakdown maintenance of plant equipment including furnaces, crushers, separators, conveyors, pumps, and pollution control systems.

Coordinate with maintenance teams to improve equipment reliability and reduce MTTR.

Support plant expansion, modernization, and technical upgrade initiatives.

5. Inventory & Material Management

Manage raw material procurement planning, feedstock inventory, chemicals, consumables, and spare parts.

Ensure accurate material balance tracking and minimize operational losses.

Optimize inventory levels to support uninterrupted operations.

6. Team Leadership & Workforce Management

Lead production supervisors, engineers, technicians, and plant operators.

Drive workforce productivity through training, performance management, and skill development initiatives.

Establish KPIs and ensure performance monitoring across departments.

Build a culture of accountability, safety, and continuous improvement.

7. Regulatory Compliance & Reporting

Ensure accurate operational documentation, production reports, environmental logs, and safety records.

Coordinate statutory reporting and ensure readiness for audits and inspections.

Liaise with regulatory authorities for operational compliance.

8. Cost Control & Budget Management

Monitor plant operating costs including energy, fuel, labor, and consumables.

Identify cost-saving and efficiency improvement opportunities.

Participate in annual budgeting, CAPEX planning, and ROI evaluation for operational improvements.

9. Cross-Functional & External Coordination

Collaborate with procurement, quality, logistics, finance, and environmental teams.

Coordinate with vendors, contractors, and government authorities for plant operations and compliance.

Support business leadership in achieving operational and sustainability goals.

Qualifications & Experience

Bachelor's Degree in Mechanical / Chemical / Metallurgical / Industrial Engineering or related discipline.

1015 years of experience in metal processing, battery recycling, smelting, or heavy manufacturing operations.

Strong exposure to plant operations, HSE compliance, and team leadership.

Proven experience in managing large-scale industrial operations.

Excellent leadership, analytical, and decision-making skills.