Torchora
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Key Responsibilities and Required Skills for Kiln Supervisor

💰 $65,000 - $95,000

ManufacturingOperationsSupervisionIndustrial ProductionEngineering

🎯 Role Definition

As a Kiln Supervisor, you will be the cornerstone of our manufacturing process, overseeing the entire kiln department's operations. You will be entrusted with managing a team of skilled operators, ensuring that our kilns run efficiently, safely, and in strict adherence to quality specifications. This pivotal role requires a leader with a deep technical understanding of thermal processing, a commitment to continuous improvement, and the ability to inspire a culture of excellence and accountability. You will be directly responsible for meeting production schedules, troubleshooting complex process issues, and collaborating with maintenance and quality teams to drive operational success.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Lead Kiln Operator
  • Process Technician (Thermal Processing)
  • Production Foreman

Advancement To:

  • Production Manager
  • Plant Superintendent
  • Operations Manager

Lateral Moves:

  • Quality Assurance Supervisor
  • Process Engineer
  • Maintenance Supervisor

Core Responsibilities

Primary Functions

  • Direct, supervise, and coordinate the daily activities of the kiln operating team to ensure production targets are met safely and efficiently.
  • Continuously monitor and analyze critical kiln operational parameters, including temperature profiles, firing curves, atmosphere, and fuel consumption, using SCADA, HMI, and other control systems.
  • Uphold stringent quality control standards by conducting regular inspections of products, interpreting quality data, and implementing immediate corrective actions to minimize defects and waste.
  • Champion a safety-first culture by enforcing all company and regulatory safety protocols (e.g., OSHA, LOTO), conducting regular safety audits, and providing ongoing safety training.
  • Collaborate with the maintenance department to plan, schedule, and oversee preventative and corrective maintenance on kilns, refractory linings, and associated equipment to maximize uptime.
  • Lead troubleshooting efforts to identify the root cause of process deviations, equipment malfunctions, and quality non-conformities, implementing robust and sustainable solutions.
  • Develop and manage shift schedules, approve timecards, and oversee employee performance, providing regular coaching, feedback, and formal performance reviews.
  • Train and mentor new and existing kiln operators on standard operating procedures (SOPs), safety practices, and quality inspection criteria to build a highly skilled and versatile team.
  • Manage and optimize the inventory of essential supplies, including refractory materials, fuel, and other consumables required for kiln operation.
  • Maintain detailed and accurate production logs, operational records, and incident reports, communicating key performance indicators (KPIs) to plant management.
  • Drive continuous improvement initiatives within the kiln department, utilizing Lean Manufacturing, Six Sigma, or other methodologies to enhance efficiency, reduce costs, and improve product quality.
  • Inspect refractory linings for wear and damage, coordinating and supervising refractory repairs and new installations to ensure kiln integrity and longevity.
  • Ensure the proper handling, storage, and processing of raw materials and finished goods in accordance with company standards.
  • Respond to and effectively manage any kiln-related emergencies, directing the team's response to ensure personnel safety and minimize equipment damage.
  • Develop, review, and update Standard Operating Procedures (SOPs) for all kiln-related tasks to ensure consistency and operational discipline.
  • Participate in the budgeting process for the kiln department, monitoring departmental spending and identifying opportunities for cost savings.
  • Analyze energy consumption data and implement strategies to improve energy efficiency and reduce the environmental impact of kiln operations.
  • Act as the primary point of contact for the kiln department across all shifts, ensuring seamless communication and transition between shift supervisors.
    s- Evaluate and recommend new technologies, equipment upgrades, or process modifications to enhance kiln performance and production capabilities.
  • Lead pre-shift meetings to communicate daily production goals, safety topics, and any pertinent operational updates to the team.

Secondary Functions

  • Collaborate with the Process Engineering team to conduct trials for new products or process modifications.
  • Assist the Quality Assurance team in customer complaint investigations and root cause analysis.
  • Participate in cross-functional plant-wide improvement projects and initiatives.
  • Support the Environmental, Health, and Safety (EHS) department by participating in incident investigations and compliance audits.

Required Skills & Competencies

Hard Skills (Technical)

  • In-depth knowledge of kiln operations, including rotary, tunnel, or shuttle kilns.
  • Proficiency with process control systems such as SCADA, DCS, and PLCs.
  • Strong understanding of refractory materials, their application, and maintenance best practices.
  • Expertise in thermal processing, thermodynamics, and combustion principles.
  • Ability to read and interpret technical drawings, schematics, and P&IDs.
    s- Knowledge of industrial safety standards (OSHA, MSHA, LOTO, confined space entry).
  • Familiarity with quality control systems and statistical process control (SPC).
  • Competency in Microsoft Office Suite (Excel, Word, Outlook) for reporting and analysis.
  • Experience with computerized maintenance management systems (CMMS).
  • Understanding of lean manufacturing principles and continuous improvement tools.

Soft Skills

  • Exceptional leadership and team management abilities.
  • Strong verbal and written communication skills.
  • Advanced analytical and problem-solving capabilities.
  • Decisive and effective decision-making under pressure.
  • Excellent interpersonal skills with the ability to coach and mentor.
  • High level of personal organization and time management.
  • Adaptability and resilience in a dynamic manufacturing environment.
  • Collaborative mindset and a strong team player.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED.

Preferred Education:

  • Associate's or Bachelor's Degree.

Relevant Fields of Study:

  • Ceramic Engineering
  • Materials Science
  • Industrial Technology
  • Mechanical Engineering

Experience Requirements

Typical Experience Range:

  • 5-7 years of progressive experience in a heavy industrial manufacturing environment, with at least 2-3 years in a leadership or supervisory capacity.

Preferred:

  • Direct, hands-on experience operating and supervising the specific type of kilns used in our facility (e.g., cement, lime, brick, or advanced ceramics). Proven track record of leading process improvement projects with quantifiable results in safety, quality, and efficiency.
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