Senior Engineer, Process

Scope of Work (Overall)

Process Ownership & Control

• Own and manage key manufacturing process parameters, including establishing control limits and operating standards for assigned production lines or areas
• Drive continuous improvement and accuracy of process documentation, including PFDs, P&IDs, SOPs, work instructions, and process control sheets.

Production Support & Troubleshooting

• Deliver day-to-day technical support to production teams, troubleshooting process upsets, quality deviations, equipment–process interactions, and throughput limitations to ensure stable and efficient operations.

Continuous Improvement & Cost Optimization

• Lead continuous improvement initiatives to increase OEE and throughput, improve yield and batch consistency, and reduce rework, rejects, downtime, and waste.

SHES & Regulatory Compliance

• Ensure all process changes and operating practices meet SHES standards, explosives licensing conditions, site security requirements, and applicable legal obligations.

Quality & Product Performance

• Ensure improvement outputs meet specifications, eliminate root causes of nonconformance, and improve process capability.

Projects & Commissioning

• Lead and support CAPEX projects, line modifications, debottlenecking, new product trials, and commissioning/qualification activities.

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Key Responsibilities

A. Process Monitoring, Stability & Optimization

• Conduct detailed analysis of daily production data (batch records, QC results, scrap/ rework, downtime causes, OEE) and evaluation of operations at Bulk Emulsion Plant and Catridged Emulsion Plant, identifying areas for improvement and recommending appropriate solutions.

B. Technical Troubleshooting & Root Cause Analysis

• Lead structured investigations for process deviations, quality rejects, customer complaints (where plant-related), abnormal incidents or near misses involving process behavior.
• Apply RCA tools (5-Why, Fishbone, Pareto, Fault Tree, DOE when required) and document corrective/ preventive actions (CAPA).

C. Process Documentation, Standards & Change Control

• Maintain and periodically review:

  • SOPs / Work Instructions / Safe Work Procedures
  • Process Control Plans, batch records, QC results
  • PFD/P&ID updates (as built), critical instrument lists

• Drive Management of Change (MOC) for any changes to raw materials, formulations, equipment settings, utilities, control logic, layout, packaging methods, or operating limits.

• Ensure changes are risk-assessed (JSA/ HAZOP/ hazard studies), validated, trained-out, and properly archived.

D. SHES, Risk Management & Compliance (Explosives Environment)

• Enforce process safety practices: safe operating envelopes, interlocks, grounding/ bonding controls, housekeeping, segregation rules, and controlled access.
• Participate in SHES initiatives (risk assessments, audits, emergency preparedness drills, incident investigations).
• Support compliance readiness for internal and external audits (licensing authority inspections, customer audits and ISO audits if applicable).
• Promote “Stop Work Policy” culture and ensure process operations are aligned with approved safe systems of work.

E. Quality Interface & Collaboration

• Work closely with QCD Department to:

  • Improve test methods and correlation to process variables
  • Reduce variability and improve first-pass yield

• Review and disposition non-conforming product with QCD Department and Plant (including rework/ regrade rules where permitted and safe).

F. Projects, Trials & Commissioning

• Support plant projects (debottlenecking, automation, layout changes, utilities upgrades).
• Run trials (new raw material sources, formulation improvements, process parameter adjustments) with documented risk review, trial plan, and success criteria.
• Identify and manage assigned projects, ensuring compliance with defined scope, completion within approved timelines, adherence to budgetary constraints, and full implementation of safety standards and regulations.
• Participate in FAT/ SAT, commissioning, validation/ qualification runs, and handover to Plant.

G. Training & Capability Building

• Provide training and guidance to production teams on new processes, procedures and equipment to ensure successful implementation and operation.
• Develop simple one-point lessons and refresher training packs after incidents/ deviations.
• Stay up to date with the latest advancements in process engineering technologies, methodologies and best practices.

H. Cross-Functional Collaboration & Reporting

• Coordinate with Maintenance/ Engineering and Plant Department on recurring breakdowns and reliability improvements linked to process performance.
• Coordinate with Supply Chain Department on raw material performance, supplier changes, and specification adherence.
• Prepare weekly/ monthly KPI reports and improvement dashboards for Plant Management.