DCS Engineer Production

Role Description

ROLE TITLE/ DESIGNATION	Unit Production DCS Engineer
GRADE	Assistant Manager/Deputy Manager
DEPARTMENT	Production
REPORT TO (JOB TITLE ONLY)	Shift In charge
LOCATION	All units

Role Purpose

To run and coordinate DCS operations, achieve targeted shift production ensuring required quality and optimizing process parameter w.r.t SOC to maximize yield performance

Key Result Areas

OBJECTIVE (AREA)	HOW (METHODS OF ACHIEVEMENT)	MEASUREMENT (END RESULT)
Implementation of safety and environmental initiatives	Near miss reporting Safety/toolbox talks Accident Reporting Ensuring PPEs compliance of self and team Attending training and providing on the job training to team	Department Safety Compliance No. of Safety Talks/ No. & Documentation for RCA Zero accidents
Production and Quality Control: Process Parameter control as Per SOP through operation control	Controls all process parameters through DCS. Histogram & run charts are monitored for key process parameters. Communicates with plant lab chemists and ensures the conforming product is diverted to the allocated silo. Maintains operational data in the log book and uploads the same in SAP. (New)checking of process/equipment interlock healthiness.	Plant shift production quality & quantity Cp Value >1.33 Shift Production rate Target shift production Achievement % & target quality deviation Report Process Reliability
Equipment monitoring and coordination with the engineering team	Filling up equipment checklist/register on a routine basis Ensuring routine abnormalities are reported in SAP Coordination engineering team on abnormalities for distribution of job Ensuring schedule change over of equipment Compliance to schedule operation activities in the shift	Achieving productivity as per plan Plant shift production quality & quantity Cp Value >1.33 Shift Production rate
Cost Reduction Initiatives	Extend filter cloth life by maintaining proper pressures and ensuring dryers are inline. Reduce consumables by maintaining nozzle pressure, oil flow, and timely checks. Optimize chemical use by stabilizing pelletizer and following SOPs for KNO3 and molasses prep. Increase yield by maintaining SOC parameters and correcting deviations. Ensure zero spillages, reprocess any waste, and maintain bag filter pressure. Avoid parallel equipment use and optimize equipment selection per process needs. Maximize gas supply to CPP and recycle wastewater.	COP within budget Zero OT Chemicals & spares consumption Useful Life of refractory Useful Life of equipment Nos of leakages and spillage Yield data Utility consumption report Reduction of specific power consumption and specific water consumption.
Implementation of Manufacturing Excellence initiatives	Primary responsibility for ensuring adequate and appropriate data entry in the SPC module Identifying operation and process bottlenecks and abnormalities	Zero Wastage Zero product defect Zero breakdown DMT & FIP Completion Reports

Organizational Chart

Designation of immediate superior to whom the position will report	Shift In-charge
Role designation	Unit Production DCS Engineer

Designation of role holders - team members who are reporting directly to the role holder	Team members Role
No Direct Reportees Except workman	1.Mixer Cleaning, KNO3 Preparation (Main & Service tank), Nozzle Changing, Module Cone Purging & Poking, Oil Pump strainer Cleaning, DBC & Surge Bin By-Pass Purging and cleaning, Quench Changing (Reactor, Mixer & Quench Tower), CBM & SFS burner Changing (Reactor & dryer), Keep stand By Quench Pipe, Oil Burner, CBM burner, Mixer Pipe ready. 2.Reactor Spares (Nozzles, Bends, Hoses, Elbow, Burner Pipe, KNO3, Phosphate) Handling Magnet Cleaning, Kno3 & Molasses pump hose changing, Boiler Blowdown, Valve Greasing and lubrication of rail. 3.Off-spec tank level, Elevator & Screw Cleaning & Observation, Conveying line & Cone Hammering, VBC inlet manhole cleaning, Gauge cleaning, Shut down a job.

Work Relationship

Contact point	Designation of person contact	Purpose of contact
Internal Production head, I/C - Production Lab CPP     Warehouse     Shift In Charge     Field Operator	Manager- Chief Manager AM/DM/ Manager  AM/DM/ Manager  AM/DM/ Manager AM/DM/ Manager Executive/ Sr. Executive	Plan & availability of materials. Product Quality, any Specific Customer requirement Off-gas consumption, Power Generation  Silo management and packing schedule Quality Deviation, Abnormalities, Schedule Jobs Field activities required and related to DCS operation
External NA	NA	NA

Experience

Basic level of education	Degree: BTech/ Diploma
Stream: Chemical/ Mechanical
Post Graduate qualification	Degree: NA
Stream: N/A
Certifications	N/A
Experience (No. Of Years)	3+ years
Functional skills	* Good communication * Machinery operation knowledge * Knowledge of Lean Manufacturing * Strong computer literacy

Competencies

Adapt and Respond Proactively

Innovate to Grow

Customer Champion

Develop and Empower People

Collaborate and Partner

English Communication(Oral)

English Communication(Written)

Ethics and Integrity

Job Knowledge

Presentability & Energy

Professionalism

Skills