DCS Engineer Production
Date: 24 Oct 2025
Location: IN
Company: phillipsca
Role Description
| ROLE TITLE/ DESIGNATION | Unit Production DCS Engineer |
| GRADE | Assistant Manager/Deputy Manager |
| DEPARTMENT | Production |
| REPORT TO (JOB TITLE ONLY) | Shift In charge |
| LOCATION | All units |
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
| OBJECTIVE (AREA) |
HOW (METHODS OF ACHIEVEMENT) |
MEASUREMENT (END RESULT) |
| Implementation of safety and environmental initiatives | 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 |
Department Safety Compliance No. of Safety Talks/ No. & Documentation for RCA Zero accidents |
| Production and Quality Control: Process Parameter control as Per SOP through operation control | Controls all process parameters through DCS. Histogram & run charts are monitored for key process parameters. Communicates with plant lab chemists and ensures the conforming product is diverted to the allocated silo. Maintains operational data in the log book and uploads the same in SAP. (New)checking of process/equipment interlock healthiness. |
Plant shift production quality & quantity Cp Value >1.33 Shift Production rate Target shift production Achievement % & target quality deviation Report Process Reliability |
| Equipment monitoring and coordination with the engineering team | 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 |
Achieving productivity as per plan Plant shift production quality & quantity Cp Value >1.33 Shift Production rate |
| Cost Reduction Initiatives | Extend filter cloth life by maintaining proper pressures and ensuring dryers are inline. Reduce consumables by maintaining nozzle pressure, oil flow, and timely checks. Optimize chemical use by stabilizing pelletizer and following SOPs for KNO3 and molasses prep. Increase yield by maintaining SOC parameters and correcting deviations. Ensure zero spillages, reprocess any waste, and maintain bag filter pressure. Avoid parallel equipment use and optimize equipment selection per process needs. Maximize gas supply to CPP and recycle wastewater. |
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 Reduction of specific power consumption and specific water consumption. |
| Implementation of Manufacturing Excellence initiatives | Primary responsibility for ensuring adequate and appropriate data entry in the SPC module Identifying operation and process bottlenecks and abnormalities |
Zero Wastage Zero product defect Zero breakdown DMT & FIP Completion Reports |
Organizational Chart
| Designation of immediate superior to whom the position will report | Shift In-charge |
| Role designation | Unit Production DCS Engineer |
| Designation of role holders - team members who are reporting directly to the role holder | Team members Role |
| No Direct Reportees Except workman |
1.Mixer Cleaning, KNO3 Preparation (Main & Service tank), Nozzle Changing, Module Cone Purging & Poking, Oil Pump strainer Cleaning, DBC & Surge Bin By-Pass Purging and cleaning, Quench Changing (Reactor, Mixer & Quench Tower), CBM & SFS burner Changing (Reactor & dryer), Keep stand By Quench Pipe, Oil Burner, CBM burner, Mixer Pipe ready. |
Work Relationship
|
Contact point |
Designation of person contact | Purpose of contact |
|
Internal Production head, I/C - Production Lab |
Manager- Chief Manager AM/DM/ Manager AM/DM/ Manager AM/DM/ Manager AM/DM/ Manager Executive/ Sr. Executive |
Plan & availability of materials. Product Quality, any Specific Customer requirement Off-gas consumption, Power Generation Silo management and packing schedule Quality Deviation, Abnormalities, Schedule Jobs Field activities required and related to DCS operation |
|
External NA |
NA | NA |
Experience
|
Basic level of education |
Degree: BTech/ Diploma |
| Stream: Chemical/ Mechanical | |
| Post Graduate qualification |
Degree: NA |
|
Stream: N/A |
|
| Certifications | N/A |
|
Experience (No. Of Years) |
3+ years |
| Functional skills |
|
Competencies
Skills
