Senior Process Operations Engineer

Role : Process Engineer

Experience : 3-6 years

Location : Gummidipoondi, Tamilnadu

Qualification : B.Tech Chemical Engineering

Preferable : Carbon Black experience

Job Purpose

Executing all process activities for smooth plant operation in producing Quality Carbon Black.

Job Context & Major Challenges

Job Context

Birla Carbon, Gummidipoondi unit was commissioned in 1998 and since then has been progressively expanded to 5 production lines, to reach its current annual production capacity of approximately 2,25,000 MT of carbon black. It is the largest carbon black manufacturing unit in India, and amongst the top 3 largest manufacturing units for Birla Carbon globally.

In addition to carbon black, the unit has power generation (co-product of carbon black manufacturing) capacity of 60.7 MW and also rubber master batch (downstream product for carbon black) capacity of approximately 15,000 MT per annum.

Birla Carbon, Gummidipoondi has implemented a management system which meets all requirements of various standards including IATF 16949 : 2016, ISO 14001 : 2004, OHSAS 18001 : 2007 to manage Quality, Environment, Occupational Health & Safety. Power generation and export is a major value driver. The unit has 60.7 MW power generation capacity, part of which is used to meet the requirements of unit and the balance is exported to the network.

Job Challenges

• To minimize off spec generation through effective participation of shift team in process change activities.
• To meet high internal customer (QC, Ware House) expectation through effective implementation of process parameters.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 Production

To implement set guidelines for trouble free operation. Analysis of critical parameter & communicating any abnormalities for immediate action in shift.

Assisting Shift In-Charge in all process activity like Grade change, Reactor Start-up, Equipment change over, changing process parameter for any change in DCS & field.

To follow all SOPs strictly as per QMS.

To follow preventive and predictive maintenance Schedule in coordination with Engg .

Routine plant rounds for identification of abnormalities and taking corrective actions with information to Shift In-Charge.

Execute and supervise Refractory / Bag fixing jobs.

KRA2 Quality Control

To implement standard practices for maintaining product quality. Assist to maintain key process parameters as per product characteristics.

Assisting in timely inspection of product quality at each process change to reduce off spec generation.

Prepare, analyse Control Chart, Run Chart and find out reason of abnormality for taking corrective action during shift in order to obtain consistent quality.

KRA3 Cost Control

Optimum utilization of Resources & waste minimization to contribute in achieving cost effectiveness. Record Keeping of cost incurred due to reprocessing, energy loss, waste generation, break down, & other quality indicators.

Kra4 Qms

Implement all systems, Procedures & Work Instructions for maintaining ideal plant operation. Understanding systems, procedures and work instructions.

Taking part in WCM, quality circle, kaizen, 5-S activities.

KRA5 Process MIS

Preparation of shift activity, events report to help in initiating improvement measures. Preparing Shift wise Production report.

Maintain shift log book for each activities in every shift.

Log sheet generation after logging the process parameter readings in DCS.

Entering the quality parameter in register after getting from shift chemist.