Senior Executive - Production - Technical Services - Agro Chemical

Job Title

Senior Executive - Production (Technical Services Department)

Location

Srikakulam Plant

Department

Technical Services

Job Purpose

To oversee and execute process commissioning, pilot trials, process optimization, yield improvement, and documentation for existing and new agrochemical products, ensuring improved productivity, reduced resource consumption, and adherence to safety and quality standards.

Key Responsibilities

1. Process Commissioning

• Lead the commissioning of new products, ensuring compliance with PSSR (Pre-Startup Safety Review) and HAZOP (Hazard and Operability Study) guidelines.
• Ensure smooth operational startup for a minimum of three new products annually.

2. Pilot Trials

• Manage the development and pilot trials for new products, including mapping, MOC (Management of Change), and HAZOP studies.
• Supervise and collect data during trials, ensuring the generation of accurate and comprehensive trial reports.
• Collaborate with R&D and other departments to finalize and implement pilot trial findings.

3. Process Optimization and Yield Improvement

• Implement strategies to reduce batch cycle times, enhance capacity, and improve yields for existing and new products.
• Troubleshoot and optimize time cycles by modifying existing facilities to maximize productivity.
• Drive capacity enhancements and process modifications to achieve tonnage improvements.

4. Raw Material (RM) Optimization

• Evaluate and optimize raw material consumption by calculating molar ratios and conducting lab trials with R&D and PD labs.
• Scale lab trial findings to plant-level implementation to achieve cost reductions.

5. Effluent and Solvent Reduction

• Use RRR (Reduce, Reuse, Recycle) methodology to minimize effluent consumption norms.
• Reduce solvent consumption norms and improve recovery percentages through modifications in distillation facilities.

6. Documentation and Standardization

• Prepare and standardize documentation for existing and new products, including product manuals, SOPs, pilot trial reports, HAZOP study reports, and PSSR reports.
• Develop and maintain comprehensive P&IDs (Piping and Instrumentation Diagrams), PFDs (Process Flow Diagrams), mass and material balance sheets, energy balance sheets, and utility and heat load calculations.

Key Performance Indicators (KPIs)

• Successful commissioning of at least 3 new products per year.
• Timely execution of pilot trials with comprehensive reporting and implementation.
• Measurable improvement in batch cycle times and product yields.
• Reduction in raw material norms and solvent consumption percentages.
• Reduction in effluent generation using RRR methodology.
• Timely and accurate preparation of standardized documents for all processes.

Qualifications and Experience

• Education: Bachelors/Master’s degree in Chemical Engineering or a related field.
• Experience: 5+ years in production or technical services in the agrochemical or chemical industry, with hands-on experience in process optimization and pilot trials.
• Skills:
• Expertise in PSSR and HAZOP studies.
• Strong analytical and troubleshooting abilities.
• Proficiency in process documentation and tools like AutoCAD for P&IDs and PFDs.
• Knowledge of solvent recovery and distillation processes.
• Team collaboration and communication skills.

Work Conditions

• Based at the Srikakulam Plant, with occasional travel to corporate offices or R&D facilities.
• Ability to work in a plant environment with strict adherence to safety protocols.

Reporting

• Reports to the Manager - Technical Services Department.