.Detailed Job Description:
Production Executive
- Job Title: Production Executive / Shift In-Charge
- Department: Chemical Production / Plant Operations
- Job Location: Village Rasal, Pali-Khopoli Road, Raigad, Maharashtra (Near Khopoli)
- Reporting To: Production Manager / Plant Head
- Employment Type: Full-time, Permanent
- Working Hours: Rotational Shift System (A, B, and C Shifts, including night shifts)
1. Comprehensive Key Responsibilities
A. Reactor Operations & Technical Troubleshooting (GLR & SLR/SSR)
- Batch Execution: Oversee the complete lifecycle of chemical batches in Glass-Lined Reactors (GLR) and Stainless Steel Reactors (SLR/SSR) from raw material charging to final product discharge.
- Thermal Shock Management: Strictly control heating and cooling ramps (utility management) for GLRs. Ensure the temperature difference (Δ T) between the jacket and the mass stays within safe limits to prevent glass lining fractures.
- Utility Operations: Manually or via DCS control the circulation of steam, cooling water, chilled water, or brine through reactor jackets and condensers.
- Distillation & Recovery: Monitor vacuum distillation, reflux ratios, and solvent recovery systems to maximize pure yield and control material balance.
- Equipment Integrity: Conduct daily visual inspections of reactor internals, agitaters, baffles, and bottom flush valves. Coordinate spark testing for GLRs during maintenance shutdowns.
B. Shift Management & Shop-Floor Leadership
- Labor Allocation: Assign duties to plant operators, field operators, and contract laborers at the start of each shift based on the production plan.
- Shift Handover: Execute a formal handover process. Document exact batch status (e.g., reaction stage, temperature, pressure), material stocks on the floor, and equipment breakdowns for the incoming shift team.
- Floor Discipline: Maintain absolute cleanliness and organization on the shop floor by enforcing 5S methodologies (Sort, Set in order, Shine, Standardize, Sustain).
C. Documentation & Quality Assurance
- BMR/BPR Maintenance: Ensure online (real-time) filling of Batch Manufacturing Records (BMR) and Batch Production Records (BPR) with zero overwriting or errors.
- Material Reconciliation: Cross-verify raw material quantities issued from the warehouse against BMR requirements. Perform end-of-shift material reconciliation.
- QC Coordination: Draw representative in-process samples from reactors safely. Coordinate with the Quality Control (QC) laboratory for analysis (pH, moisture, viscosity, GC test results) and secure clearances before transferring products.
D. Process Safety, EHS & Compliance
- Static & Purging Hazards: Enforce mandatory nitrogen purging and verify electrical grounding/earthing continuity before charging any volatile solvents or hazardous powders into reactors.
- Work Permits: Authorize and monitor Safe Work Permits (Confined Space Entry, Hot Work, Height Work, Cold Work) for any maintenance activities required during the shift.
- PPE Enforcement: Ensure 100% compliance with Personal Protective Equipment (PPE) like chemical-resistant suits, hand gloves, safety goggles, and face shields among workers.
- Emergency Response: Act as the first responder during shift emergencies (chemical spills, runaway reactions, gas leaks). Follow Emergency Response Plans (ERP) and report incidents to EHS and management immediately.
2. Required Candidate Profile & Competencies
Educational Qualifications:
- Minimum: B.Sc. / M.Sc. in Organic / Industrial Chemistry OR Diploma in Chemical Engineering.
- Preferred: B.E. / B.Tech in Chemical Engineering / Chemical Technology from a recognized institute.
Work Experience:
- Minimum 2 to 7 years of solid, hands-on production floor experience in a Specialty Chemical, Agro-Chemical, Surfactants, or Active Pharmaceutical Ingredients (API / Bulk Drugs) manufacturing plant.
- Candidates with specific experience in Ethoxylation, Alkylation, or Esterification reactions will be given high preference.
Technical & Functional Skills:
- Equipment Expertise: Proven history of independently handling GLRs and SSRs of capacities ranging from 2 KL to 20 KL.
- Engineering Drawings: Basic ability to read and interpret Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs).
- Control Systems: Working familiarity with DCS (Distributed Control System) or PLC-based plant operations is highly desirable.
- Software: Basic computer literacy (MS Excel, Word). Experience using SAP ERP (Production Planning / PP Module) for material booking is a strong plus.
Behavioral Skills:
- Strong leadership and conflict-resolution capabilities to handle factory labor unions and contract workers.
- Excellent situational awareness and high-pressure decision-making skills.
- Clear verbal communication skills in Marathi and Hindi to instruct floor workers effectively.
3. Key Performance Indicators (KPIs) for the Role
- Production Targets: 100% adherence to the monthly batch production schedule.
- Batch Quality: Maintaining a Right-First-Time (RFT) batch success rate above 98% (minimizing batch rejections/rework).
- Safety Record: Zero lost-time injuries (LTI) or major chemical spillage incidents during the assigned shift.
- Yield Optimization: Keeping raw material and utility consumption within standard budgeted limits.
Pay: ₹10,042.90 - ₹50,343.39 per month
Work Location: In person
