Senior Executive / Assistant Manager - Production

JobItUs; Bharuch District; On-site; INR 1,200,000 - 1,700,000; Full time

Job summary

JobItUs in India requires a hands-on process leader to manage the Alumina/Zeolite production stream. You will stabilise processes, troubleshoot complex issues and drive safety, quality, productivity, capacity and cost improvements.

You will lead a team of engineers and operators, coordinate with maintenance and quality teams, and push continuous improvement through Lean/Six Sigma methods.

Qualifications

• 6-8 years of experience in process manufacturing / chemical manufacturing.
• Experience in Alumina, Catalyst, Specialty Chemicals or Inorganic Chemicals.
• Hands-on experience in plant operations and process troubleshooting.
• Experience managing production teams and shop-floor activities.
• Experience in process optimization, productivity improvement or capacity debottlenecking.
• Strong analytical and problem-solving capability.
• Ability to work effectively with Maintenance, Quality, R&D, Engineering, EHS and Supply Chain functions.

Responsibilities

• Own daily/monthly production plan for Alumina/Zeolite stream and ensure stable operation.
• Drive improvements in OEE, throughput, and cost per MT.
• Lead plant trials, process optimization and implementation.
• Coordinate with Maintenance for preventive/breakdown maintenance.
• Lead and develop production engineers, supervisors and operators.
• Ensure compliance with EHS standards, SOPs and PTW procedures.
• Deliver measurable improvements in safety, quality, delivery and cost.

Skills

Plant operations

Process troubleshooting

Team leadership

Analytical thinking

Cross-functional collaboration

Data analysis

Education

B.E./B.Tech. in Chemical Engineering

Lean Six Sigma certification

Tools

DCS/PLC automation

Data analytics

Job description

Lead and manage the Alumina/Zeolite production stream to achieve safe, reliable and cost-effective manufacturing while meeting production and quality targets. The role will have end-to-end operational responsibility for the entire manufacturing process, with strong focus on process stability, yield improvement, productivity, equipment utilization, cost optimization and continuous improvement.

1. Production & Process Management

• Own and deliver the daily/monthly production plan for the Alumina/Zeolite stream.
• Ensure stable operation of precipitation, hydro synthesis, filtration, washing, drying and calcination processes.
• Monitor critical process parameters and ensure operation within defined process limits.
• Optimize manpower, equipment, raw materials and utilities for maximum productivity.
• Drive reduction in process losses, downtime and production variability.

2. Process & Quality Improvement

• Troubleshoot process and product-quality issues using data-driven RCA.
• Identify process-quality correlations and establish robust operating windows.
• Lead plant trials, process optimization and implementation of process improvements.
• Work closely with Quality, R&D and Process Development teams for product/process development.

3. Productivity & Cost Optimization

• Drive improvement in OEE, throughput and cycle time.
• Reduce energy, water, raw material and manpower consumption per MT.
• Identify and eliminate process bottlenecks.
• Lead capacity debottlenecking and productivity improvement initiatives.
• Identify and implement cost-saving opportunities within the production stream.

4. Equipment & Reliability

• Ensure optimum utilization and availability of production equipment.
• Coordinate with Maintenance for preventive and breakdown maintenance.
• Identify chronic equipment/process losses and drive permanent corrective actions.
• Support equipment modification, commissioning, scale-up and capacity enhancement projects.

5. Safety & Compliance

• Ensure zero-compromise compliance with EHS standards, SOPs and safe operating practices.
• Drive safety observations, risk identification and corrective actions.
• Ensure compliance with MOC, LOTO, Permit-to-Work, PPE and statutory requirements.
• Lead investigation and closure of process-related incidents and near misses.

6. People & Team Leadership

• Lead and develop production engineers, supervisors and operators.
• Build team capability through training, coaching and skill-matrix development.
• Establish clear accountability for Safety, Quality, Delivery and Cost.
• Develop a culture of ownership, discipline, problem-solving and continuous improvement.

7. Continuous Improvement

• Lead Lean / Six Sigma / Operational Excellence initiatives.
• Use tools such as RCA, 5-Why, Fishbone, Pareto, CAPA and Kaizen.
• Identify opportunities for process simplification, automation and digitalization.
• Deliver measurable improvements in capacity, cost, quality, productivity and resource consumption.

Key Performance Indicators

• Safety: Zero major safety incidents; safety action / observation closure.
• Production: Production plan achievement; throughput / capacity utilization; OEE and equipment availability.
• Quality: RFT / First Pass Quality; off-specification reduction; product quality consistency.
• Cost & Productivity: OPEX / cost per MT; energy and water consumption per MT; raw material yield; manpower productivity.
• Improvement: Process improvement projects; cost savings / productivity gains; capacity debottlenecking; downtime reduction.
• People: Skill-matrix improvement; training completion; team engagement and performance.

Technical Competencies

• Alumina/Zeolite precipitation and crystallization; solid-liquid separation and filtration; cake washing and impurity removal.
• Drying and moisture control; calcination and thermal processing.
• Particle Size Distribution - D10/D50/D90; BET / Surface Area; Pore Volume; LBD / CBD; LOI and chemical purity.
• Process mass balance and yield calculation; DCS / PLC-based process control; industrial troubleshooting and process optimization.

Equipment Exposure Preferred hands-on exposure to:

• Reactors / Precipitators Filter Press / Vacuum / Pressure Filters Washing Systems Dryers / Spray Dryers Calciners / Rotary Kilns Material Handling & Dust Collection Systems.

Experience & Candidate Profile

• 6-8 years of experience in process manufacturing / chemical manufacturing.
• Preferably experience in Alumina, Catalyst, Specialty Chemicals or Inorganic Chemicals.
• Strong hands-on experience in plant operations and process troubleshooting.
• Experience in managing production teams and shop-floor activities.
• Demonstrated experience in process optimization, productivity improvement or capacity debottlenecking.
• Strong analytical and problem-solving capability.
• Ability to work effectively with Maintenance, Quality, R&D, Engineering, EHS and Supply Chain functions.

Preferred Qualifications

• B.E./B.Tech. in Chemical Engineering.
• Lean Six Sigma certification is an advantage.
• Experience with DCS/automation and data analytics is an advantage.

Ideal Candidate

A hands-on process leader who can independently manage the Alumina/Zeolite production stream, stabilize processes, troubleshoot complex production problems and continuously improve Safety, Quality, Productivity, Capacity and Cost.