Plant Manager

We are looking for a

Job Title

Plant Manager  

Location

Moxi   

A. Purpose /Role of the job /: 

Lead & direct all plant operation activities, ensuring that production forecast is aligned with S&OP (Sales & Operation) processes and are produced timely, in a cost effective & innovative manner, maximizing operational excellence benchmarking with global standards, in strict compliance with quality specifications, in a safe & environmentally sound workplace complying with laws of the land. Plant and assets are cared & maintained in top conditions aligned with Global standards, keeping employees motivated & updated in their skillset to contribute their best at the highest standard set for manufacturing facility.

B. Environment/Context/Complexity of the job: 

Internal: Compliance with quality standard ISO-9001 and adherence to Environment Management System (ISO -14001:2004)

Knowledge of certification and compliance of Energy standard ISO-50001 for efficient use of energy.

Strictly meeting conditions of “Consent to Operate” set by GPCB/MOEF

External: As Factory Manager, meeting all the statutory requirements of law/regulations, liaison with Statutory Authorities, Factory Inspectorate, GPCB, Ministry of Labour, Law enforcing authority, Disaster Management group, neighboring industry. 

C. Responsibilities/ Accountabilities of the job: 

1. Key Result Areas: Incident free operations, Adherence to INEOS Styrolution SHE guideline, Compliance with local regulations.

Major Activities:

• Ensure regular safety training at site for employees, contractors and visitors on
  • Safety rules and guidelines
  • Operating procedures
  • Incident sharing and learning
  • Permit to work and Risk Assessment etc.
• To develop safety culture at site and drive for incident free operation.
• To prepare annual SHE improvement plan for the site.
• To meet SHE KPIs and Targets set by management from time to time.
• Drive Behavior Based Safety program at site.
  • Organize training at site to take BBSO to next level of reporting – shop floor level and contractors
• Act as head of Site SHE committee to resolve safety issues and drive SHE performance.
• To ensure all incidents including Near Miss at site are reported, investigated and action items are tracked to closure.
  • Drive use of KMS for incident reporting and investigation, MOC, action item tracking
  • Ensure SHE related action items from audits, plant walkthroughs etc are tracked to closure.
• As an Asset Manager for Nandesari, responsible for the overall integrity of the site.
  • Accountable for INEOS Styrolution Asset Care program.
  • Assign responsibility to respective engineers for maintaining the asset and integrity of the protective system.
• Ensure site procedures are aligned with INEOS Group Guidance Notes (IGGNs).
• Accountable for,
  • Cascading INEOS 20 principles at site through site rules and procedures.
  • Implementation of Life Saving Rules at site.
  • Safety of employees, Contractors and Visitors at site
  • Following Permit to work as per the site procedure.
  • Following Management of Change as per the site procedure
• Responsible for
  • Conducting HAZOPs at site as per procedure
  • Track action items from HAZOP to closure.
• Ensure compliance to legal regulations.
  • Operation of waste water treatment plant and other air and water treatment facilities in line with the permit requirements.
  • Adherence to site licenses and permits.

• Responsible to promote INEOS Styrolution Sustainability program at site.

Outcome:

      Zero incident/accident in the plant.

2. Key Result Area: Asset Manager for site

Major Activities:

• Responsible & accountable for the overall integrity of asset in the plant.
• Lead all asset area owners, Asset Engineers & process engineers.
• Responsible for all human and technical aspects of the asset.
• Ensure first priority is the health and safety of all its employees, of the contractors, the third parties, the public as well as the environment that may be impact by the asset activities.
• Ensure that the right organisation is in place and the adequate resources are available for maintaining a good integrity level in the asset.
• Visibly promote and encourage all actions that will improve the asset integrity and communicate up to the operator level
• Ensure procedures for asset integrity are in place in line with IGGN’s, PS 10 principle, legal requirements.
• Form & Lead the PSM (Process Safety Management) steering team for site to discuss the incidents, issues and suggestions, put action items to improve asset integrity and process safety
• Periodically interact and communicate process safety with operators and supervisors.
• Put KPI’s for periodic monitoring of asset integrity, Preventive maintenance and initiate actions for improvement as required.
• Periodically review the findings of integrity inspection and ensure action plans are in place.
• Lead MOC process of the site & ensure closure of the same before start-up activity.

Outcome:

Zero Process Safety incident/accident in the plant.

3. Key Result Areas : Managing Plant Operations (Compounding)

Major Activities:

• Direct, plan & ensure production of different grades of finished product, meeting stringent quality standards as per sales forecast.
• Direct, plan & ensure startup & shut down activities of the plants including shut down maintenance activities to ensure smooth operation of the plant in alignment with sales requirements.
• Direct, plan & ensure efficient utilization of Raw material & energy to achieve yield & energy targets.
• Coordination with Marketing, procurement & logistics, Quality, SHE, maintenance, HR, GTO, Global counterparts.

• Establish & maintain ISO 9001 Quality management system, work procedures, best working practices, Trouble shooting.

Outcome:      

Smooth operation meeting marketing requirements, matching with global benchmarking KPIs & high productivity & safety standards, meeting stringent quality standards.

4. Key Result Areas: Process Development/ new products trials.

Major Activities

• Plan DoE (Design of Experiment) for the trials after aligning with S&OP and Business team to enable the Business to confirm approval for such trials
• Develop Design of Experiment for such trials in consultation with APAC team and GTO
• Support Business by taking necessary Plant trials for New Grade & New Color Development aligning with RDC , SCM & Business.
• Conduct such trials in alignment with SCM and S&OP process with complete information of requirement of time, quantity of transition material and any other development impact on present production

Outcome:  

Improved product and processes

5. Key Result Areas: Manpower planning, development of the people and succession planning.

Major Activities:

• On the job & classroom trainings, mentoring & follow up, Understand & address employee grievances, Performance assessment & motivation of subordinates.
• Establish open & disciplined culture, Administration of Shift schedules, and leaves of Subordinates. 
• Training and skill development of employees for taking up more responsible function, growth and succession planning      

Outcome:

       Improved & sustainable production activity with high employee morale.

6. Key Result Areas: Plant Performance

Major Activities:

• Controlling/Achieving KPI targets, material balance, specific consumption of RM and Utilities reporting as per requirement of SAP.
• Make sure that all safety and quality procedures and instructions are implemented in all the departments.
• Preparation of Production & KPI reports.
• Planning & Coordination with global & local SAP team & consultants, Service desk team, Regional coordinators.
• Maintain harmonious industrial relations within his Department.

Outcome:

Improvement on plant performance (Reliability and Availability).

D. Dimensions: Describe the most representative figures of the job (for example: number of staff, budget you’re responsible for, number of projects,)

Supervision of staff: Give the number of people you supervise (“Direct” means that they report directly to you, “Indirect” means they report to someone who reports to you.)

E. Main contacts /Interfaces: What are the internal en external contacts you have, necessary for reaching your results?

F. Required profile:

Level of education & Knowledge:

• Bachelor of Engineering from reputed institute (prefer Chemical, Petroleum or Polymer)

Experience in general:

• About ~ 20 years of work experience in Compounding, Chemical or similar industries.

Technical skills:

• Thorough knowledge of Continuous and Batch processes.
• DCS Operations, HAZOP, P&ID study, Process Safety, IMS documents.
• Competent to use Microsoft software

Competencies, Behavioral skills: (acc. to competency profile and required level of descriptions)

• Safety mindset for self and others.
• Leadership and coaching skills.
• People Management.
• Team player and learning attitude.
• Effective Communication : Good written and oral communication skills
• Critical Thinking: Makes effective decisions with limited information and takes initiative when situations are not clear.  Make timely, tough decisions.  Receive guidance from others for difficult or unusual problems.
• Influence: Effectively develops relationships that build rapport, gain support and motivate others to adopt initiatives impacting multiple organizations.
• Managing Priorities: Develops timelines, sets milestones, and acquires resources for complex or long-term projects.

Legal Training requirements:

• Under the provision (111-A) of the Factories Act 1948, reading with Gujarat Factory Rules 1963 about General Health & Safety, Emergency response, handling of hazardous substance.

G. Performance indicators: Describe the criteria allowing to measure to what extent the results are achieved - related to the accountabilities.

• Smooth operation meeting marketing requirements, matching with global benchmarking KPIs & high productivity & safety standards, meeting stringent quality standards.
• Zero incident mind-set-culture in compliance with INEOS Styrolution, government laws & various SHE & process safety audits.
• Improvement on plant performance (Reliability and Availability) and achieve production volume as per S&OP requirement and improved yield.
• Continuous improvement in various areas of manufacturing process and utilities.

If you require further information please contact Ruchi Sharma.

Of course, your application will be treated confidentially.

Human Resources

ruchi.sharma@ineos.com