Process Engineer-Saponification Unit

Duties and Responsibilities

• Production Management - Plan and execute daily production activities in line with the approved production plan. -
• Ensure achievement of production volume, efficiency, and utilization targets. - Coordinate raw material availability
• With Supply Chain and Warehouse teams. - Ensure uninterrupted operation of the saponification unit. - Act on behalf of
• The Production Manager during his/her absence when delegated.
• Process Engineering & Optimization - Monitor and optimize all process parameters to maximize productivity and
• Product quality. - Analyze process trends and implement improvements to increase capacity and reduce losses. -
• Standardize operating parameters and process control methods. - Lead process troubleshooting and corrective actions
• For operational issues. - Develop and update Standard Operating Procedures (SOPs).3. Quality Management - Ensure soap base meets all quality specifications. - Work closely with the Quality team to
• Investigate deviations and implement corrective actions. - Drive First Time Right (FTR) performance. - Reduce
• process variation through data-driven process control.
• Asset Reliability & Maintenance - Coordinate with the Maintenance team to improve equipment reliability. -
• Monitor equipment performance and downtime. - Lead Root Cause Analysis (RCA) for major equipment failures. -
• Ensure execution of preventive and predictive maintenance plans. - Support commissioning of new equipment and
• process modifications.
• Team Leadership - Supervise and coach Process Operators and Shift Leaders. - Develop operators through
• Structured training and competency assessments. - Monitor workforce performance and ensure compliance with SOPs.
• Foster teamwork, accountability, and continuous improvement.
• Safety, Health & Environment (SHE) - Ensure compliance with all safety, environmental, and operational
• Procedures. - Lead safety observations, risk assessments, and incident investigations. - Ensure proper handling of
• Chemicals, steam, and utilities. - Promote a strong safety culture and compliance with company HSE standards.
• Cost & Material Management - Monitor raw material consumption against standards. - Reduce process waste and
• Improve material yield. - Optimize utility consumption, including steam, water, electricity, and compressed air. -
• Support inventory management and material reconciliation.
• Continuous Improvement - Lead Lean Manufacturing and TPM initiatives within the unit. - Identify opportunities to
• Improve productivity, quality, safety, and cost. - Implement corrective and preventive actions from RCA findings. -
• Drive process automation and digitalization initiatives where applicable.
• Reporting & Performance Management - Prepare daily, weekly, and monthly production performance reports. -
• Monitor KPIs and communicate performance to management. - Maintain production records and SAP transactions. -
• Present improvement initiatives and operational performance during management reviews.