Process Engineer

Key performance area

1. Plan and manage NCP plants to ensure process efficiencies, targets are met and increased production volumes.

• Ensure world class plant Overall Equipment Effectiveness/Asset utilisation by ensuring:
• Maximum plant availability by minimising plant breakdowns/Downtime.
• Production plant targets are achieved whilst meeting specified efficiencies.
• Products meet quality specifications.
• Responsible for the conversion of raw material to finished products.
• Ensure effective cost control by ensuring efficient and effective raw material usage.
• Work in collaboration with Procurement to ensure adequate raw material availability to ensure production targets are met.
• Manage product inventory.
• Manage plant data and report on variances on a daily, weekly & monthly basis.
• Work in collaboration with Production Planner to implement Preventative maintenance and maintenance of systems.
• Report on causes of plant down time and implement actions to minimise the downtime.
• Troubleshoot process issues summarize and draw conclusions from test results leading to effective technical resolution of process problems.
• Analyse process parameters and trends (Temperature, Pressure, Flow, Amps, Level, valve response, ORPs, pH, Conductivity, Mass, switches, monitors etc) in order to:
• Ensure Optimum plant operation.
• Anticipate breakdowns and plan stoppages for repairs.
• Identify erratic behaviour and fine tune controller responses.
• Identify deviations and work in collaboration with the Production supervisor and develop corrective actions.
• Work in collaboration with Supply chain Specialist/Marketing/Customer services to ensure:
• Customer requirements are met (OTIF)
• Root cause investigations are conducted to address Customer complaints.
• Participate in Root cause investigations and provide feedback information to relevant steak holders.
• Ensure Electronic logbooks (Moodi etc) are correctly filled by plant personnel and report on deviations.
• Generates required MOCs for the successful plant operation.
• Develop layouts and standards to support a Lean manufacturing environment.
• Coach plant personnel in solving technical problems.
• Support and manage process-based fault finding.
• Ensure the implementation of process improvement initiatives in all plants in the area of responsibility.
• Introduce best practice into plant operations in order to optimise it.
• Support the improvement Team and work together with Expertise Centres to solve problems in their areas of specialisation (e.g., collaborating with reliability engineers to solve reliability problems).
• Work in a network with other Process Engineering role representatives in the works and within the global business to increase the knowledge of the plant operation.
• Perform Standard Costs analysis, and ensure Manufacturing and Quality Engineering, and Production Operations.
• Interact cross functionally and with internal and external customers; and serve as a consultant for engineering or scientific interpretations and advice on significant production matters.
• Plan work schedules, expenditures, attend meetings, and prepare monthly\weekly reports as required.
• Ensure reports are written and submitted to Section Manager on time (production reports, quality reports, plant EH&S reports, variance reports, downtime reports, project reports etc) on a weekly/monthly basis as required.
• Act in various functions within the department when required and necessary. Act as Section Manager/Production Planner/Production Supervisor/Senior Process Controller/Process Controller/Material Handler when required.

2. Achievement and management of unit operational plans and resources.

• Ensure continuous improvement of production Units efficiency.
• Ensure that all work is done correctly and that it is completed within legal, regulatory and company requirements. (Process safety issues and concerns must be addressed and communicated to all.)
• Planning, monitoring and evaluating the performance of direct reports.
• Work in collaboration with training practitioner in developing training requirements of production team members by identifying their training needs and forwarding them to the section manager.

1. Ensure quality improvement during production and ensure the maintenance of quality systems, and practices which meet customer, and regulatory requirements.

• Improved product quality
• High level compliance to quality systems
• Quality management systems policies and procedures implemented.
• Address Audit findings and implement corrective actions.
• Improved production processes
• Continuous improvement initiatives
• Ensure product conforms to certification standards (NSF) and ensure monthly monitoring samples of plant NSF certified products are submitted for analysis.
• Ensure customers receive product On Time in Full (OTIF)
• Ensure proper document control and maintenance thereof within the Section.

3. Ensure high level compliance to applicable Legal Legislation, Responsible care, Safety, Health, Environmental and Process safety standards in area of responsibility.

• Work in collaboration with plant SHEP officers to ensure plant risk assessments are in place and updated.
• Ensure Health and Safety, Environmental and Process Safety hazards/aspects are identified and mitigated.
• Ensure plant Safe Operating Procedures and Emergency Procedures are in place and updated.
• Ensure plant Process Hazard Analysis (HAZOPs and Process Hazard Reviews) are in place, updated with corrective actions implemented.
• Ensure plant Process and Instrumentation diagrams (P&ID) are in place and updated.
• Ensure section Functional Design Specification documents are in place and updated.
• Ensure and implement strategies for pollution prevention (Air, ground and water pollution).
• Ensure plant compliance to the Air Emission License (AEL), Water Use License (WUL), Major Hazard installation (MHI).
• Work in collaboration with plant SHEP coordinator to ensure plant Aspect and Impact register is updated.
• Participate in internal and external audits, and surveys (ISO 9001, ISO 14001, ISO 45001, Major Hazard Installation, NSF, Isokinetics, Customer audits etc) and implement corrective actions.
• Ensure incidences are reported on time.

4. Project implementation and management.

• Lead/Assist with the implementation of projects in the area of responsibility to ensure they are completed on time and within budget.
• Communicate future permanent and temporary changes on the plants by making effective use of the MOC process.
• Facilitate meetings to ensure that process improvement ideas are generated and implemented to ensure continuous improvement at NCPs production facilities.
• Leads the development of highly capable manufacturing processes for new products through frequent interaction with R&D.
• Plan and implement complex and significant projects to reduce manufacturing costs, improve processes, increase product quality and reliability, and enhance process capability.
• Participate in PLT and Continuous Improvement project team in multi-disciplinary initiatives to develop and implement plant improvement initiatives.
• Related SHERQ responsibilities

Knowledge / skills/ Competencies

• Knowledge of environmental health and safety processes
• Understanding of the Manufacturing industry
• Knowledge of relevant legislation and regulations (e.g. OHS Act and regulations)
• Knowledge of the chemical composition, structure, and properties
• Knowledge of chemical processes and transformations including chemicals and their interactions, danger signs, production techniques, and disposal methods.
• Knowledge of arithmetic, algebra, geometry, calculus, statistics, and their applications.
• Knowledge of environmental health and safety processes
• Understanding of the Manufacturing industry
• Knowledge of relevant legislation and regulations (e.g. OHS Act and regulations)
• Knowledge of cost implications and business processes
• Knowledge of impact on profitability on an organization
• Knowledge of ISO standards
• Continuous Improvement and Auditing processes
• Investigating RCIs, issues and non-conformances
• Computer literacy, SAP, Microsoft
• SAP R3
• Excellent Communication skills.
• Judgment
• Organisational Communication Effectiveness
• Initiative
• Interpersonal communication skills
• Analytical Ability
• Results Driven
• Organisational values and quality
• Professionalism
• Attention to Detail
• Confidentiality
• Personal Ethics
• Cost awareness
• Facilitation skills.
• Proactive problem-solving abilities use initiative
• Good time management skills deadline driven.
• Quality and results orientated.
• Decision making
• Self-motivated, energetic and positive
• Reliable / responsible / dependable / trustworthy
• Team worker
• Able to handle conflict management.
• High level of integrity
• Focus on best business practice and ethics.
• Excellent interpersonal and communication skills.

Experience

• 3-5 years in a Manufacturing/Chemical environment

Qualifications:

• Matric
• BSc/BEngTech/BTech/Advanced Diploma in engineering (Chemical)

Reporting structure:

• This position reports to the Northern Plants Manager.

Personal Circumstances:

• Must be able to obtain a satisfactory medical report from the companies medical centre.