Process Engineer

BASIC FUNCTION 1.0To ensure per shift operation complies with HSE regulation and rules and support in achieving Goal Zero target through various Risk assessmentsDeveloping, optimizing and improving manufacturing processes to enhance productivity, quality and safetyIdentifying and implementing process improvements to reduce costs, minimize waste and increase efficiency.Conduct detailed analysis and evaluation of existing manufacturing processes, identifying areas for improvement and recommending appropriate solutionsCollaborating with cross-functional teams / PAD team, taking support from regional process experts to ensure smooth translation of new grades, recipe optimizations. Make strategies for new grade developments, record observations and circulate reports with teamsParticipate in cross-functional teams to drive root cause analysis and corrective actions, suggest any checks addition or deletion in preventive measures based on breakdown analysis. Basic Function 1.1Monitoring and analyzing process data, identifying trends and proposing solutions for process improvements on extruders, feeders and equipments, suggest for spares modifications and develop vendors for meeting requirementsPerforming process capability studies, statistical analysis and data-driven decision-making to achieve operational excellence and help to meet production targets.Ensuring compliance with safety, environmental and regulatory requirements in all process engineering activities.To review quality parameters of FG and suggest steps to improve in areas not meeting quality specifications. To ensure the plant in a high safety standard and by promoting the awareness amongst employeesReview departmental KPI’s month on month basis and suggest improvement in areas requiring improvementExecute trainings for team as per skill matrix and gaps observed Act as reliver in shifts when requiredRESPONSIBILITIES AND ACCOUNTABILITIES 1.0Follow HSE regulation in daily work, right use of PPE’s, reporting near miss, BBS so as to achieve Goal Zero targetFollow and maintain permits systems implemented on site for effective implementation of OEModify and upgrade ,maintain line processing condition with SOP for grades & Report fand act on deviations and corrections formalize strategies fir next runMaking of defect free production, Monitor and measure parameters and report for abnormalities with corrective actions, RCA’s , resolve with help of Production SupervisorSupporting in reduction of Scrap and Off spec generation by Optimizing process conditions, changes needed time to time, Tracking daily Scraps, Rework and downtime. Report to Supervisor and Manager for support and reconciliation of material per POReview change over activities efficiently, suggest for reduction of time by using smart tools, train the team , plan effectively per changeovers and safely complete itPlan / modify / suggest for downstream equipments, plan for CAPEX / debottlenecking with help of Supervisor/Manager, Initiate and anticipate for MOC need and complete all actions on timeRESPONSIBILITIES AND ACCOUNTABILITIES 1.1FG handling with proper packaging and labelling, manage shop floors with right material to deliver, work closely with Logistics and QAFilling out of formats, report, documentations, assist in making Monthly, weekly and daily reports, validate data each month for correct reportingSupport in Dust reduction drive and 5S, OCS drive and support LEAN methodologySupporting in successful implementation of new development product Assist Production Supervisor / Production Manager to maintain all Standards like ISO 9001,14001,GMPSupport in cost saving initiatives, actively drive VEP initiative, cost saving projectsMaintain all data as per LYB Data retention policyPERSON SPECIFICATION:Education:Diploma /Degree in Plastics Technology / Polymer engineeringWork Experience: The position requires minimum 5 to 10 years of relevant experience in the plastics industry from masterbatch industry.Thorough knowledge with hands on experience of Extruder operations, screw configurations and associated work, Loss in weigh feeders, Under water pelletizers system along with trouble shooting.Certifications in ISO, 7QC tools ,LEAN- 6Sigma will be an added advantageLicenses & Certifications:Functional Core Competencies & Level mapping: BasicMaster batch processing like Additive, Fillers & White MBAutomation in MBLoss in weight Feeder (Ktron / Brabender) OperationUnder water palletization / strand palletizerMixersBasic Process Automation and understandingUtility knowledge along with DCS operationsBasic EnglishMS Office ,Reports making with analysis SAPSkills:Report writing , permit filling, supervision, format filling ,Report generation from SAP for analysis and take corrective actions,Amicably resolve issues for corrective actions with help of other stake holdersCommunication SkillAnalytica thinking and conflict managementExperience with process improvement tools and methodologies such as Kaizen, 5SSolid understanding of quality management systems, such as ISO standardsStrong attention on details and documenting sameProven ability to identify, analyze and solve problems Ability to learn and adaptability in fast-paced industrial environmentsAbility to work in tough and pressure situations to meet targets and resolve problemsLanguages:Good command on local language along with Basic English as well

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