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Production Engineer

Company:

INEOS Oxide

Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?

Organizational context
and job purpose

INEOS Organization:

INEOS is a global manufacturer of petrochemicals, specialty chemicals and oil products. It comprises 15 businesses each with a major chemical company heritage. Its production network spans 65 manufacturing facilities in 16 countries throughout the world. INEOS products make a significant contribution to saving life, improving health and enhancing standards of living for people around the world. Its businesses produce the raw materials that are essential in the manufacture of a wide variety of goods: from paints to plastics, textiles to technology, and medicines to mobile phones - chemicals manufactured by INEOS enhance almost every aspect of modern life.

BUSINESS CONTEXT:

Ethylene oxide (EO) is an important building block for the preparation of a wide variety of EO derivatives (EODs), including various surfactants, as well as a host of other chemical intermediates including Glycol Ethers, Polyethlene Glycols, Ethanolamines, and Alkyl Alkanolamines. 

INEOS Oxide is one of the world’s leading producers of Ethylene Oxide (EO) and Ethylene Oxide Derivatives (EODs).  We currently have a total EO and EOD capacity of 920 kta spread across five different production units throughout Europe and the US. These units have leading cost economics, due to economies of scale, state-of-the-art technology, strategic locations, etc. Our EO project in the US is targeting the fast growing merchant EO market, building on our experience and leadership position in Europe.

Purpose of the Job:

Most Important Internal Factors

  • The Production Engineer will monitor, troubleshoot, and optimize operating units to drive process and product improvements.  During a typical day they will apply technical knowledge to detect causes of deviations in quality, capacity, yield, and energy consumption.    

Most Important External Factors

  • The candidate is responsible for safe and efficient operation of assigned production unit using established operating discipline and procedures. The Production Engineer is responsible for maintaining the plant assets and protective systems integrity and to deliver established production targets set by the business.

Responsibilities and Accountabilities

Accountability 1

Safety, Health & Environmental

Most important activity

  • Maintain and control the safe and efficient operation of the production unit using established operating disciplines and procedures.  Ensure safety and environmental compliance is achieved.
  • Responsible for maintaining the plant assets and protective systems integrity.
  • Assist in defining and maintaining the correct operating envelopes for the organization.  Investigate when deviations outside of the operating envelopes occur.
  • Participate in the development of operating procedures and training materials.
    • Support PSM and Environmental efforts including Process Hazard Analyses (PHAs), Management of Change process, Risk Assessments and incident investigations.
    • Input, evaluate and approve MOCs
    • Conduct PSSRs for MOCs
    • Participate in PHAs as the process engineering representative
  • Understand and lead by example for all safety and environmental programs.
  • Investigate all SHE incidents.
  • Routinely collect, report, and address SHE near misses.
  • Complete all assigned action items from PHAs, incidents, audits, etc in a timely manner and keep status and plans for action items updated.
  • Maintain safety as the highest priority of the plant
  • Maintain the 20 Principles of Safety
  • Conduct routine AsCare tours and participate in audits.
  • Adhere to and uphold all safety policies and standards

Accountability 2: 

Manufacturing Excellence

  • Deliver established production targets for asset while complying with quality specifications.
  • Troubleshoot process problems with Production Specialists, Quality, Maintenance and operations teams.
  • Cross train and provide backup for the Production Engineer role for all assets.
  • Benchmark, identify and implement best in class improvements and practices to improve the operation and efficiency of the unit.
  • Actively provide input and participate in operator development and training programs with operations and training personnel.
  • Lead and/or participate in root cause investigations.
  • Assist in identifying and closing performance gaps, which can include project development and execution.
  • Provide data to validate that the projects deliver performance objectives after implementation.
  • Provide technical support and coach site personnel on measurements and updates of technology performance and asset utilization data.
  • Track unit efficiency and identify opportunities to optimize the operations of the plant to minimize cost and waste.
  • Identify key performance indicators and develop a monitoring process to ensure potential deviations are handled proactively.
  • Utilize engineering practices to understand plant bottlenecks and present solutions to increase plant capacity.
  • Track production losses and first pass prime to identify opportunities for improvement and drive solutions to improve product supply reliability and first pass prime.
  • Evaluate typical analytical data annually and update typical values as needed.
  • Provide support to operations during upset conditions, start-ups and T/As. This includes serving as a back-up for the plant production specialist.
  • Utilize modelling software as needed to predict the performance of the various process equipment.
  • Support capital projects as the production representative.
    • Provide normal operating conditions
    • Provide maximum pressures/temperature/flows, etc. for equipment design

Skills/Competencies

Level of Education & Experience in general

  • BS Chemical Engineering
  • 1 year or co-op plant process experience (new graduate)

Technical Skills

  • Training Skills
  • Keen computer skills with knowledge of MS Office
  • Process modelling using Aspen software
  • Basic knowledge of equipment sizing
  • Basics knowledge of distillation column operations
  • Basic knowledge of PSM
  • Process troubleshooting

Behavioral Skills

  • Exceptional communication skills, both oral and written
  • Strong mechanical aptitude
  • Safety role model
  • Problem solving skills with data analysis ability

ADA Physical requirements, visual acuity requirements and environmental conditions

Outside

Light Work:  Exerting up to 20 pounds of force occasionally, and/or up to 10 pounds of force frequently, and/or a negligible amount of force constantly to move objects

  • The worker is subject to inside environmental conditions:  Protection from weather conditions, but not necessarily from temperature changes.
  • The worker is subject to outside environmental conditions:  No effective protection from the weather.
  • The worker is subject to both environmental conditions:  Activities occur inside and outside.
  • The worker is subject to extreme cold:  Temperatures below 32 degrees F for periods of more than one hour.
  • The worker is subject to extreme heat:  Temperatures above 100 degrees F for periods of more than one hour.
  • The worker is subject to noise:  There is sufficient noise to cause the worker to shout in order to be heard above the ambient noise level.
  • The worker is subject to hazards:  Includes a variety of physical conditions, such as proximity to moving mechanical parts, electrical current, working on scaffolding and high places, exposure to high heat or exposure to chemicals.
  • The worker is subject to atmospheric conditions:  One or more of the following conditions that affect the respiratory system or the skin:  fumes, Odors, dusts, mists, gases, or poor ventilation.
  • The worker is subject to oils:  There is air and/or skin exposure to oils and other cutting fluids.
  • The worker is required to wear a respirator.
  • The worker is required to don a gas mask.

Inside:

Sedentary Work:  Exerting up to 10 pounds of force occasionally and/or a negligible amount of force frequently or constantly to lift, carry, push, pull or otherwise move objects, including the human body.  Sedentary work involves sitting most of the time.

Subject to inside environmental conditions:  Protection from weather conditions, but not necessarily from temperature changes

Employee must have the ability to see written documents, computer screens, and to adjust focus.

Hearing: Perceiving the nature of sounds at normal speaking levels with or without correction.   Ability to receive detailed information through oral communication and to make discriminations in sound.

PERFORMANCE INDICATORS

Measurement and success along with improvements will be monitored by the Manager. Following are the Primary Key Performance Indicators for this position:

  • Achieve SHE metric targets for safety and environmental incidents
  • Meet or exceed plant production goals
  • Meet or exceed production supply reliability
  • AsCare, 20P, MOC/PSM compliance achieved
  • Meet or exceed efficiency targets
  • Completion of assigned action items
  • Achieve plant department and personal metrics as defined in annual performance assessment

Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance.On our team, people are acknowledged for embracing new practices that help create real value for customers.