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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.
Job Responsibility
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
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
What we offer
$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
Amazing benefits that start within 30 days of hire
6% company match on 401k
3 weeks PTO (increases to 4 weeks on 4th anniversary)