Purpose of the Job:
The Process engineer is a technical specialist who reports to the Technical Services Manager and has the primary responsibilities to:
Design and implement plant changes to minimize the need for maintenance shutdowns thus maximizing plant uptime and output.
Provide specialized technical services, operations support, process control and effluent waste monitoring services for the organization.
Lead the energy management framework and ensure its alignment to group policy.
Implement world class systems and manage operational excellence to ensure operation performance is met in terms of both output and efficiency through effective production, engineering, and distribution.
Support and optimize plant performance and energy balance via resources and projects.
Investigate deviations on plant quality, chemistry and operational processes, and prepare technical reports with proposed preventative measures.
Become the technical custodian of the Chlor-Alkali manufacturing knowledge base.
Assist in ensuring business compliance with legal and SHERQ requirements in terms of the manufacturing process.
The abovementioned activities shall be conducted in compliance with the Occupational Health and Safety Act, No. 85 of 1993 and all relevant policies and procedures. This position profile acts as a guide to the role only, and additional work outcomes may be required to be performed by the incumbent.
Key Performance Areas:
Provide technical services on site.
Ensure process control philosophy is developed and well understood.
Ensure technical support to any process trains that require investigation and improvement.
Investigate repeat failures, incidents and customer complaints, implementing preventative measures.
Monitor raw material and final product quality, acting upon deviations accordingly.
Provide reports on any process deviations on the system.
Measure, evaluate, and report on the effluent management on site and identify opportunities for effluent reduction.
Standards and Codes of Good Practice:
Make use of site drawings, engineering standards and the technical library to assist plant operations in achieving the required standard.
Responsible for the development and control of P&IDs, HAZOP studies and design reviews for updates on the system as per the operational strategy development.
Assist in the development of Electrolyser protection, manufacturing data, and quality parameters according to OEM standards.
Implement and monitor operating technology systems (i.e., MES, Track and Trace, SCADA, operational systems).
Continuous Improvement and Operational Excellence:
Provide technical input to ensure that operations are legally compliant and adhere to certification requirements.
Lead the energy management framework and ensure alignment to the Bud Group's energy policy.
Become the technical custodian on Chlor-Alkali manufacturing and ensure knowledge management and technical expertise are embedded in the organisation.
Identify opportunities to improve the overall business through low-cost or agile processes to maximize uptime and output.
Design and implement a plant operational capability that allows for statutory maintenance to be completed without stopping production.
Implement world class manufacturing principles.
Knowledge / Skills / Competencies:
Extensive knowledge of the Occupational Health and Safety Act, No. 85 of 1993.
Extensive knowledge of ISO 9001 and quality management system.
Extensive knowledge of hazardous chemical manufacturing and handling codes, preferably in a Chlor-Alkali plant.
Knowledgeable about different types of equipment related to chemical manufacturing plants.
Skilled in hazard identification, risk assessment, and root cause analysis.
Ability to read and interpret engineering drawings and technical databooks.
Experience in operational excellence, energy management, and world class manufacturing principles.
Experience in managing and coordinating projects and continuous improvement activities.
Experience in using SharePoint and Corrective Action Systems (i.e., Digilex).
Knowledge of Operations Technology (i.e., SCADA, PLC, SAP IM, and MES).
Experienced in relationship building and cross-collaboration at a senior level.
Extensive knowledge of the OHS Act and legal appointments.
In-depth knowledge of Operations Technology (OT), MES systems, SCADA database, ERP software, and Dashboard reporting.
Sound understanding of project management, contractor management, supplier management, change principles, and continuous improvement.
Computer literacy in SAP and MS Office (Word, Excel, Outlook).
In-depth knowledge of process engineering, HAZOP studies, and LOPA.
Strategic management, planning, coordination, and control.
Technical custodian with the ability to travel locally and internationally to technical conferences.
Excellent communication and interpersonal skills.
Leadership and Team player.
Concern for standards and thorough attention to detail.
Ability to work under pressure.
Highly analytical and innovative.
Experience:
15 years in a chemical manufacturing plant environment (chlor-alkali manufacturing). Experience in quality management and laboratory operations. Experience in world class systems and operational excellence implementation. Experience in developing and using an MES system for analysis of operational data. Familiar with financial budgeting and capex management.
Qualifications:
Matric
BSc or BEng in Chemical Engineering (regrettably no BTech)
Project management / PRINCE II certification and/or experience
Professional Engineer (PR Eng)
Reporting Structure:
This position reports to the Process Technical Services Manager.
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