About the role
Department: Operations / Production Industry: Wire rod mill Experience: Ideally 7–15 years in wire rod/special steel rolling, with at least 5-10 years in a shift-in-charge. (Independently)
Key Responsibilities
- Shift Operations
- Take complete charge of wire rod mill operations during the shift from reheating furnace to finished coil handling.
- Ensure safe, stable and efficient operation of the complete mill.
- Monitor production, yield, mill utilization, cobble rate, quality and energy consumption.
- Coordinate with Maintenance, Quality, Electrical, Utility and Dispatch teams for smooth operation.
- Hands-on experience in high-speed wire rod block operation, including:
- Block stand setup and pass-line control
- Roll gap setting
- Guide setting and alignment
- Loop control and tension control
- Inter-stand speed/tension coordination
- Block temperature management
- Twist-free rolling and dimensional control
- Block cobble prevention and troubleshooting
- Ability to identify causes of dimensional variation, ovality, tension problems, loop instability, cobbles and surface defects.
- Experience in rebar production, preferably special-grade rebar.
- Knowledge of pass design(basic), guide setting, finishing temperature, dimensional control and mechanical-property control.
- Ability to handle grade changes and rolling instability.
- Special Steel Rolling – Critical Requirement Candidate should have actual experience in rolling special grades, preferably:
- Alloy steel or Stainless Steel.
He should understand the differences between carbon steel and special-steel rolling, particularly:
- Reheating practice
- Soaking and furnace temperature control
- Descaling
- Rolling temperature
- Finishing temperature
- Cooling strategy
- Grade-change practices
- Surface-defect prevention
- Dimensional control
- Metallurgical requirements.
Special Technical Knowledge I Would Make Mandatory
The candidate should be able to independently explain and troubleshoot:
Furnace → Roughing → Intermediate → Finishing → Wire Rod Block → Laying Head →Coil Conveyor → Coil Handling
He should understand the effect of:
- Billet temperature
- Temperature drops between stands
- Roll gap
- Pass reduction
- Rolling speed
- Inter-stand tension
- Loop height
- Guide alignment
- Roll wear
- Water cooling
- Descaling
- Finishing temperature
- Cooling rate
- Laying-head speed
- Coil formation parameters
on quality, productivity and cobble generation.
Quality Knowledge
Candidate should be capable of investigating defects such as:
- Surface cracks
- Longitudinal cracks
- Seams
- Slivers
- Scratches
- Rolled-in scale
- Dimensional variation
- Ovality
- Coil shape/formation defects
- Mechanical-property variation
- Decarb/oxidation-related issues
- Stainless-steel surface defects.
He should be familiar with root-cause analysis, 5 Why, Fishbone, CAPA and process-control methods.
Safety & Shift Management
- Strong knowledge of rolling-mill safety and LOTO.
- Conduct pre-startup inspection after shutdown/maintenance.
- Ensure all guards, guides, cooling systems, emergency systems and interlocks are healthy before mill startup.
- Lead emergency response during cobble, roll failure, guide failure, water failure, power failure, etc.
- Manage manpower and allocate operators according to mill requirements.
- Ensure compliance with SOP, SWP, PPE and safety standards.
Production & Improvement
The person should be capable of improving:
- Mill productivity
- Yield
- Mill utilization
- Cobble rate
- Energy consumption
- Rejection/rework
- Changeover time
- Rolling stability.
Experience in TPM, OEE, Kaizen, continuous improvement would be an advantage.