DCS Engineer Production

Role Description

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

1.Object:
Implementation of safety and environmental initiatives 
1.How:
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
1.Final Results:
Department Safety Compliance 
No. of Safety Talks/ 
No. & Documentation for RCA 
Zero accidents

2.Object:
Production and Quality Control: Process Parameter control as Per SOP through operation control
2.How:
Controls all process parameters through DCS. Histogram & run charts are monitored for key process parameters. 
Communicates with plant lab chemist and ensures the conforming product is diverted to the allocated silo.
Maintains operational data in the log book and uploads the same in SAP.
2.Final Results:
Plant shift production quality & quantity
Cp Value >1.33
Shift Production rate 
target shift production Achievement % & target quality deviation Report

3.Object:
Equipment monitoring and coordination with the engineering team 
3.How:
•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 
3.Final Results:
•Achieving productivity as per plan  
•Plant shift production quality & quantity
•Cp Value >1.33
Shift Production rate

4.Object:
Cost Reduction Initiatives 
4.How:
•Increase filter cloth life: Maintaining required pulsing air pressure, Delta Pressure, Module inlet pressure, ensuring zero moisture carry over with air through ensuring dryer inline
•Reduction in consumption of operating consumables – Ensure required nozzle pressure, smooth oil flow and nozzle checking by field operator in time
•Optimizing chemical consumption through stabilizing pelletizer operation to optimize molasses operation and ensuring the preparation of KNO3 and Molasses is as per the SOP/Process Specification
•Increase in yield – maintaining process parameter as per the SOC and taking corrective action as soon as the deviation is observed
•Ensuring zero spillages – Ensure bag filter pressure as per the SOP
•Reprocessing of spillages
•Ensuring no parallel equipment operation
•Maximizing gas supply to CPP
4.Final Results:
•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

5.Object:
Implementation of Manufacturing Excellence initiatives
5.How
•Primary responsibility for ensuring adequate and appropriate data entry in the SPC module
Identifying operation and process bottlenecks and abnormalities
5.Final Results:
•Zero Wastage
•Zero product defect
•Zero breakdown
•DMT & FIP Completion Reports

Organizational Chart

Work Relationship

Experience

Competencies

Skills