Process Improvement Engineer

Department:  Engineering
Date:  Jun 27, 2024

Location - Hyderabad

 

Principle Responsibilities:

 

Supporting a high standard Process Safety Management and Process Hazard Analysis

  • Support the implementation of Process Safety Management (PSM) program, specifically the Process Safety Information (PSI) and cyclical Process Hazard Analysis (PHA) process, in alignment with goals from the Process Safety organization
  • Develop capability and ensure process hazard data/process safety information collected full compliance with all corporate Health, Safety, Security and Environmental System standards 
  • Provide technical support to tollers to drive compliance with local law and regulations in Health, Safety, Security and Environmental.

Driving Continuous Improvement

  • Drive development, scale-up and commercialization of best engineering solutions for process/chemistry improvement, yield improvement, sustainability/process safety improvement, capacity expansion and unit operating cost (UOC) reduction with the support from tollers and other functions
  • Apply fluently approaches of data-based decision making to identify and execute continuous improvement initiatives
  • Prioritize improvement opportunities by applying defined business drivers, affordability & timing

Leading Technology Transfer and Implementation

  • Lead/execute technology transfer from FMC to Tollers or within FMC by working with other functions
  • Be accountable of best option analysis through Request for Proposal (RFP) process for sitting studies
  • Provide verification, guidance and coaching on process design, equipment selection and sizing, control logic design, piping, utility requirements and preparation of construction packages for assigned projects (utilize FMC’s Capital Deployment Methodology as required)
  • Ensure all steps of MOC process are completed for new project implementation, including HAZOP, PHA and lessons learned meetings
  • On-site support of the commissioning of production units during Pre-Startup Safety Review (PSSR), trial production, optimization, and validation. Help establish standard production rates & efficiencies which can be used for performance monitoring
  • Ensure QAR’s, QC and Contamination Prevention policies are appropriately incorporated at the toll site.
  • Encourage adoption of FMC’s EHS programs and support as needed to ensure proper execution of TTP/Processes.

Supporting Tolling Manufacturing and Driving Standardization across sites

  • Drive standardization of process engineering technology, process, and tools in coordination with the Technical Guardianship group
  • Support tolling manufacturing operations through supplemental review of performance data to identify and develop short- and long-term improvement plans to further optimize various processes
  • Demonstrate ability to quickly understand new technologies/ TTP and legacy processes and intermediates – must demonstrate the ability to learn on the fly.
  • Develop necessary trial plans to test optimization ideas, lead testing with the toller, analyze data, and create reports of findings
  • Lead and/or participate in Root Cause Failure Analysis (RCFA) for significant safety, quality, or manufacturing failures
  • Support periodic site audits for compliance with applicable regulations and FMC standards
  • Management and tracking of ongoing qualification efforts from initial testing and assessment by the R&D organization through production scale trials.
  • Develop project execution plans to support aggressive timelines including identifying required resources and managing risks
  • Work with internal groups to assess and track opportunities and risks such as cost impacts, relative quality, supply continuity, etc.
  • Utilize database decision making to identify and resolve problems.
  • Other tasks as assigned

Requirements:

  • Technical Degree (BE/ME ) in Chemical Engineering / related field.
  • 12+ years of experience in a chemical environment with reactive chemistry process experience.
  • Good knowledge of equipment design, scale-up, troubleshooting and project management skills
  • Experienced knowledge of the technical field and working knowledge of business processes, technologies, and applications.
  • Strong safety orientation in OSHA and PSM.
  • Demonstrated commitment to Personal Safety & Environmental issues
  • General understanding of business processes and economic factors affecting the business
  • Strategic agility with foresight and the ability to create alternate plans
  • Experience presenting at both informal and formal training settings
  • Effective team building skills with an operating style that fosters high expectations, open dialogue, creates a strong sense of team, inspires, and motivates
  • Knowledge of quality assurance programs or statistical quality control
  • Experience making data-based decisions
  • Lean six sigma certification a plus