Key Responsibilities and Required Skills for Hot Rolling Specialist

🎯 Role Definition

The Hot Rolling Specialist is the designated subject matter expert for the entire hot rolling process, from the reheat furnace to the downcoiler. This individual is accountable for ensuring the stability, capability, and continuous improvement of the hot strip mill's performance. By integrating a deep knowledge of metallurgical principles with hands-on process control, the Specialist analyzes performance data, spearheads troubleshooting efforts for complex issues, and develops best practices. This role collaborates extensively with Operations, Maintenance, and Quality Assurance teams to meet and exceed production, padrões, and customer specifications, directly influencing the final product's dimensional accuracy, mechanical properties, and surface quality.

📈 Career Progression

Typical Career Path

Entry Point From:

Process Engineer
Rolling Mill Operator (Senior)
Metallurgical Engineer

Advancement To:

Senior Hot Rolling Specialist / Technical Manager
Rolling Mill Superintendent or Manager
Process Engineering Manager

Lateral Moves:

Quality Assurance Manager
Continuous Improvement Manager
Technical Sales Engineer (Rolling Mill Equipment)

Core Responsibilities

Primary Functions

Monitor, analyze, and optimize all critical process parameters of the hot rolling mill, including reheating furnace operations, descaling, roughing/finishing mill stands, and downcoiler performance.
Lead complex root cause analysis investigations for quality-related defects, dimensional inaccuracies, and process deviations, implementing robust corrective and preventive actions.
Develop, refine, and standardize rolling schedules and mill setup models (pass schedules, temperature profiles, rolling speeds) to improve product yield, throughput, and energy efficiency.
Serve as the technical liaison between the Operations team and the Level 2/3 automation systems, troubleshooting model-performance issues and specifying new functionalities.
Champion a culture of safety by actively participating in safety audits, risk assessments, and incident investigations, ensuring all rolling operations comply with company and industry safety standards.
Drive continuous improvement initiatives using methodologies like Six Sigma or Lean Manufacturing to reduce costs, minimize waste, and enhance Overall Equipment Effectiveness (OEE).
Provide expert-level technical guidance and hands-on support to mill operators and maintenance personnel during normal operations, planned outages, and emergency situations.
Manage the lifecycle of critical mill components, such as work rolls and backup rolls, by analyzing wear patterns, optimizing grinding practices, and collaborating with procurement on technical specifications.
Conduct comprehensive trials for new steel grades, technologies, or process modifications, meticulously documenting procedures, analyzing results, and presenting findings to management.
Utilize Statistical Process Control (SPC) and data analysis tools to monitor long-term process capability and identify trends or shifts that could impact product quality.
Collaborate closely with the Quality Assurance department to align process capabilities with customer specifications and internal quality standards.
Evaluate and recommend capital expenditure projects for new equipment, technology upgrades, or process enhancements to improve safety, quality, and productivity.
Act as the primary point of contact for technical inquiries from customers, sales, and product development teams regarding the capabilities of the hot rolling mill.
Perform regular audits of the rolling process and equipment conditions to ensure adherence to best practices and identify opportunities for improvement.
Support the maintenance team in diagnosing complex equipment failures and developing long-term reliability improvement strategies for mill machinery.

Secondary Functions

Develop and deliver technical training programs for mill personnel to enhance their understanding of hot rolling theory, quality criteria, and standard operating procedures.
Create and maintain detailed technical documentation, including Standard Operating Procedures (SOPs), process control plans, and technical reports.
Analyze production and quality data to generate regular performance reports, dashboards, and presentations for the plant leadership team.
Stay abreast of up-to-date industry trends, technological advancements, and new research in the field of hot rolling and metallurgy.
Facilitate the transfer of best practices and technical knowledge between different shifts, crews, and other company facilities.

Required Skills & Competencies

Hard Skills (Technical)

Hot Rolling Theory & Practice: Expert-level understanding of the principles of plastic deformation, heat transfer, and microstructural evolution during hot rolling.
Metallurgical Principles: Deep knowledge of steel metallurgy, phase transformations, and the impact of composition and processing on final mechanical properties.
Process Control Systems: Proficiency with Level 2 and Level 3 automation and control systems used in modern hot strip mills.
Data Analysis: Strong ability to analyze large datasets using tools such as PI System, Minitab, Python, or advanced Excel for SPC and process optimization.
Rolling Mill Technology: In-depth knowledge of rolling mill equipment, including reheat furnaces, mill stands, loopers, run-out-table cooling systems, and downcoilers.
Root Cause Analysis (RCA): Mastery of structured problem-solving methodologies (e.g., 5-Whys, Fishbone, Fault Tree Analysis) to resolve complex issues.
Steel Grade Knowledge: Familiarity with the production requirements for various steel grades, including low-carbon, high-strength low-alloy (HSLA), and Advanced High-Strength Steels (AHSS).

Soft Skills

Advanced Problem-Solving: A tenacious and analytical mindset geared toward diagnosing and resolving complex, multi-faceted operational and quality challenges.
Communication & Influence: Excellent verbal and written communication skills, with the ability to convey complex technical information clearly to diverse audiences, from operators to senior management.
Leadership & Mentoring: Ability to lead cross-functional teams, mentor junior engineers, and provide authoritative guidance to operational staff.
Project Management: Capability to manage technical projects from conception to completion, including trials, upgrades, and improvement initiatives.
Adaptability: Thrives in a fast-paced, 24/7 manufacturing environment and can effectively manage shifting priorities and urgent operational needs.

Education & Experience

Educational Background

Minimum Education:

Bachelor's Degree in a relevant engineering or scientific field.

Preferred Education:

Master's Degree in Metallurgical or Materials Engineering.

Relevant Fields of Study:

Metallurgical Engineering
Materials Science & Engineering
Mechanical Engineering
Chemical Engineering

Experience Requirements

Typical Experience Range:

5-10 years of progressive, hands-on experience in a steel manufacturing environment.

Preferred:

Significant direct experience working in a Hot Strip Mill (HSM), Steckel Mill, or Plate Mill environment is strongly preferred.
A proven track record of successfully leading process improvement projects that resulted in measurable gains in safety, quality, yield, or cost.
Experience with the production of specialty or advanced steel grades (e.g., AHSS, Dual Phase, Electrical Steels) is a significant asset.