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INEOS Styrolution is the leading global styrenics supplier, with a focus on styrene monomer, polystyrene, ABS Standard and styrenic specialties. With world-class production facilities and more than 90 years of experience, INEOS Styrolution helps its customers succeed by offering solutions, designed to give them a competitive edge in their markets. At the same time, these innovative and sustainable best-in-class solutions help make the circular economy for styrenics a reality. The company provides styrenic applications for many everyday products across a broad range of industries, including automotive, electronics, household, construction, healthcare, packaging and toys/sports/leisure. In 2020, sales were at 4 billion euros. INEOS Styrolution employs approximately 3,600 people and operates 20 production sites in ten countries.
A. Purpose /Role of the job /: Supervise all plant processes in coordination with Production Manager for safe and smooth running of manufacturing operations. Take care of safety, product quality, housekeeping and asset care. Troubleshooting in day to day operation for smooth run of the production. Support DCS operation and coordinate with Field Operators and Maintenance technicians. Improve on Raw material consumption, yield and reduction of off spec/off grade production. |
B. Environment/Context/Complexity of the job: Describe the most important internal and external factors influencing the job.
Internal
Compliance to INEOS Styrolution ‘SHE guidelines’.
Compliance to Quality standard ISO 9001 and Environment Management System (ISO 14001).
Compliance of Energy standard ISO 50001 for efficient use of energy.
Inter-site and company best practices transfer.
External
S&OP processes in place to deliver required raw material for continuous production in order to meet the production plan.
Supply of Utilities may be disrupted by external supplies: Electricity, Natural Gas, Water, etc.
C. Responsibilities/ Accountabilities of the job: Describe the main results expected from the job
Major Activities:
Outcome: Zero incident/accident in the plant with sustainable and safe operation. |
Major Activities:
Outcome: Prime production with desired quality, raw material & energy saving. |
Major Activities:
Outcome: Provide safe and smooth startup/shutdown, monitoring & minimizing off-grade/off-spec generation and zero incident. |
Major Activities:
Outcome: Reduction of off grade/off-spec generation. Reduction of downtime of plant equipment, Improved product consistency. |
Major Activities:
Outcome: Production data recorded properly to maintain history of the operating conditions and parameters. Data can be used immediately to identify issues and in the future to identify trending issues in the plant and/or quality complains investigations. Data is a quality record for ISO audits. |
Major Activities:
Outcome: Improve quality of communication for intended implementation of plans and investigations. |
D. Dimensions: Describe the most representative figures of the job (for example: number of staff, budget you’re responsible for, number of projects…)
Facts | Number or amount in € |
Rubber Production | Capacity: 27 kTA P-60 powder |
- Base rubber and Agglomeration | 6 PB reactor + 1 Agglo reactor |
- Graft | 3 reactors |
- CWD | Coagulation Phase-I,II; Centrifuges-7; Dryer-I |
- Powder packing | Powder Silos- 5, Powder tankers- 2 |
- Raw Material storage area | Butadiene, Styrene, ACN , AA, KOH,H2SO4,NaOH. |
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.)
Direct (Per shift) | Indirect | Total |
DCS Operator: 8 Field Operator: 5 Storage Operator: 1 | Hydro jetting supervisor: 1 | 15 people |
E. Main contacts /Interfaces: What are the internal and external contacts you have, necessary for reaching your results?
Who | Frequency of contacts | My role in those contacts [1]
| Purpose of contacts |
Production Manager | As per plant requirement | C,I | Coordination of Production activities |
Production Deputy Manager | As per plant requirement | C,I | Coordination of Production activities |
DCS Forman | As per plant requirement | R,A,C,I | Execution of Production activities |
Field Operator | As per plant requirement | R,A,C,I | Execution of Production activities |
Contract supervisor | As per plant requirement | R,A,C,I | Execution of Production & Maintenance activities |
SHE | As per plant requirement | C,I | SHE compliance & Safe operation of plant |
Maintenance team | As per plant requirement | R,A | Maintenance for reliable operation of plant |
QA Team | As per plant requirement | Quality of product | |
External: | |||
ISO Auditors | As per plant requirement | A,C,I | ISO Norms compliance |
DCS and Instrument Contractors (testing) | As per plant requirement | A,C,I | Maintenance for reliable operation of plant |
Project Engineers (CapEx projects) | As per plant requirement | A,C,I | Project activities at site |
F. Required profile:
Level of education & Knowledge:
- B.E.Chemical
- Hindi, Gujarati
- English (Desired)
Experience in general:
- 7 to 8 years of Shift Leader experience of chemical plant operation
- 2 to 3 years of DCS operation experience of chemical plant operation.
- 2 to 3 years of experience of handling of SAP system.
Technical skills:
- Safety awareness and continually reminds employees and contract worker to work safely using proper procedures when performing all tasks at shop floor.
- Production planning and to achieve the production target as per quality parameters &
Standard operating procedures with safe and efficient operation.
- Supervised and administering staff and plant equipment operation/machines throughout production process.
- Knowledge of polymerization process and utilities operations.
- Planning and supervision of shift activities in coordination with the other departments (Mechanical, Instrument, Electrical, QC/QA, Store, Utility, WWTP, Dispatch, HR, EHS, Project & Contract).
- Troubleshooting in shift activities at DCS and Shop floor.
- Shutdown and startup activities planning and follow up with Maintenance/Project team to shut down/prepare the equipment for maintenance work and return it back to operating condition.
- To ensure follow of the safe working procedures for handling chemicals.
- To ensure optimum utilization of skilled and unskilled manpower and Enabled proper utilization of resources, reducing wastage.
- Compliance to the work permits and ensures that all safety and quality measures were adhered during production process.
- Able to do Risk Assessment (JSA), HAZOP, Incident Investigation.
- Having working experience with ERP based system SAP.
- Able to operate software like KMS, SAP, MOC, NEAR MISS.
- Able to do ISO documentation work.
- Able to monitor, tracking and analysis of process parameter.
Competencies, Behavioral skills: (acc. to competency profile and required level of descriptions)
- Planning and Organizing.
- Problem analysis and possible solution.
- Responsible and reliable.
- Communication skill - verbal & written.
- Team work.
- Learning attitude.
- Conflict management, People management
- Positive attitude towards safety norms and work procedures for self and others.
- Result oriented and Target achievement.
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.
Job Requirements
- Must be able to climb ladders and stairs.
- Must be able to walk up to 8 hours a day.
- Be able to lift up to 25 kg (desirable).
- Be able to work in confined spaces (desirable).
G. Performance indicators: Describe the criteria allowing to measure to what extent the results are achieved - related to the accountabilities
- Performance KPIs.
- SHE KPIs.
- Asset care audit.
- Reliability of plant.
- Production volume as per S&OP plan
- Cleaning cycle time of reactors
- Housekeeping.
- Down time reduction.
- Cost saving.
[1] R – Responsible for getting tasks done (in terms of practically doing things)
A – Accountable for the task (approver of costs)
C – Consulted for the task
I – Informed about the task
If you require further information please contact Ruchi sharma.
Of course, your application will be treated confidentially.
Human Resources
ruchi.sharma@ineos.com