Process Engineer

General Scope:

Support in implementation and participate in the continuous improvement effort in the areas of Safety, Quality, Environment and Health Management System (for example SS506 part 3, ISO 9001, ISO14001, OHSAS 18001, IATF 16949).

To have a legal obligation to act in a responsible manner for the safety of themselves and other persons who may be affected by their actions or omissions at work.

Assist the Management in ensuring that Major Accident Hazards are reduced to As Low as Reasonably Practicable (ALARP) and escalate when necessary.

Ensure compliance to Customer Specific Requirements (CSR).

Main Duties & Responsibilities:

General Duty

Member of the production leadership team that formulates the goals and strategies for the department.

Shall be familiar with production plant technically, and has the responsibility to support production team appropriately to improve the plant safety, quality and efficiency

Has the responsibility to support research and development in manufacturing technology in the facilities of the plant

Safety and environment management

Provides plant process operation support to achieve safe and stable operations and quality products

Manage operation and Safety, Health and Environment related issues and solve if any problem arises

Review abnormality report, non-conforming product report, accident/ incident report, support investigation and propose corrective and preventive measures

Planning for operational Non-regular work, provide work instruction and training to Supervisor and technicians via toolbox meeting

Support regulatory requirement such as water efficiency management plan, energy conservation act and Workplace safety and health act (Major hazard installation regulation)

ISO14001 implementation

To identify the environmental aspect of its activities in the department, including activities it can influence taking accounts planned or new developments or new modified activities and product.

To provide appropriate control to the significant aspect identified

To ensure proper environmental documentation and records are filed

To ensure proper monitoring and measuring of the operations that have significant environmental impacts.

Operation Support

Setup and maintain operating conditions, guides, check sheets and logs sheets in collaboration with shift teams to ensure environment, health, safety, quality and productivity requirements are met

Administration control and monitoring of DCS system, to ensure changes to DCS / SIS sequence and settings are properly documented. Alarm optimized to prevent nuisance alarm.

Trouble shooting of production process and quality problem

Assist in training the shift team members through new/revised procedures, abnormality report, one-point lesson sheets and work instruction. Educate production operation shift and day team employees on proper methods in which to operate process and machinery. Provides relevant operational training and guidance to team members to accomplish production goals.

Lead and support ASDM work, assigned by superior, including planning and certain work Instructions making to include various phases including push back, purge, LOTO, leak test, N2 replacement, flushing, filling and commissioning

Provide leadership in production committee to facilitate programs or implement action items driven through respective committee

Support ISO 9001 and IAFT16949 implementation

Offer operational support related to raw material supply changes or troubles

Process Improvement

Responsible for process optimization and capacity improvement projects in the plant

Lead the operational MOC and ensure action plan related to the change has been implemented

Implement cost reduction measures or projects to reduce the cost of production

Analyze data and implement debottleneck effort of the production process

Initiate improvement effort for products quality

In close cooperation with technical department members, support and implement new product / process plant trials.

Prepare monthly Production Uptime report. Perform analysis and come out with improvement solution. If needed, work with Technical division (and its relevant department) to reduce the equipment downtime.

Capital expense project (Capex management)

Follow up of assigned capital expense project and related documentations including non-regular work, capex form, MOC form and risk assessment checksheet and obtain necessary approval b) Carry out preliminary process design and identify potential hazards / risk

Liaise with Vendors for preliminary quotes, specification and drawings of the capital jobs

Control the budget allocation and schedule for the capex project

Coordinator for project execution as the key contact between contractor and plant group (Shift team, maintenance department, QC department, EHS department)

Ensure completion of project including documentation update such as updating process safety information

Production spares and tool management

Manage and check assigned production spares or consumable to ensure enough to support daily operations

Coordinate calibration / repair of production tools or equipment assigned to day process group

Additional reference of OE duty & responsibility in compare with PE and DS.

Identify and develop area of improvements (including production rate) to effectively utilize equipment, materials, and manpower to maximize production without compromising EHS and quality.

Evaluate current production activities and make recommendations for EHSQ and efficiency improvements. (Note: common job scope for Sr. Day Supervisor/SDS too)

Provide engineering support for production, maintenance, and other improvement activities to ensure maximum production, improve EHSQ and cost savings and other efficiency.

Ensure shift teams are following the existing process control parameters. (Note: New process control parameters is established by Process Engineers or new installation PIC)

Liaising with SDS on process control suggestion for improvement and work with engineers in other department to make necessary adjustment on the existing process control parameters. E.g. interlock pressure setting etc. Changes on the existing process control parameter is to follow AKSS’s MOC/NRW procedure.

Determine which machines, equipment, etc. will be used and where they will be stationed in the facility. If necessary, collaborate with Technical division (and/or its relevant department) to ensure the right machine/equipment is being procure & use.

Diagnose origin of operational breakdowns, including human factor. Troubleshoot the problems with relevant department(s) and implement resolution plan that assigned to him/her. h) Keeping abreast of advancements in engineering and production and sharing knowledge with co-workers.

Identify unsafe operations and practices and report the same to Manager immediately.

Assists Assistant Operation Manager and/or Production Manager in budget preparation and monitor expenses and profitability.

Follow and adhere to all state, federal and company enforced EHSQ rules and regulations.

Collaborate with engineers from other department(s) on daily and/or per needs basis to achieve safe and stable operation and produce high quality products. E.g., during NRW period, improvement projects implementation, commissioning, etc.

Develop operational strategies to achieve production and financial objectives.

Establish new operating procedure/Work Instruction/Check Sheet and risk assessment for production activities. (Note: SDS- to review and update existing procedure/check sheets/RA, also to develop simple new procedure/check sheet/RA)

Develop operational best practices to improve production capacity, quality, and reliability.

REQUIREMENTS

Degree in Chemical / Mechanical engineering or its equivalent

Minimum 2-year experience as operation engineer in a chemical processing plant

Good knowledge of chemical engineering, mechanical engineering and / or polymer science

Experience in a process safety management, quantitative risk assessment such as LOPA (layer of protection analysis) or safety case preparation will be advantageous

SCEM, or Steam engineer/ boiler attendant certificate, preferable

Working knowledge in ISO9001, ISO14001, SS506-Part 3, cost control and regulations

Highly motivated, energetic individual, with inquiring mind set and willingness to take up new challenges

Good interpersonal and communication skills

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