Job Description

JOB DESCRIPTION / MAIN TASKS LIST
Objectives of the Position
Responsible for Organizing, implementing, and monitoring of operational activities in coating area by proper allocation of resources in shifts (working in shift). Leading the shift activities to achieve defined KPI's by optimal utilization of resources and material following the EHS standards and requirements.
Main Tasks
1. Production Management

• Ensuring and arranging the production activities at coating lines to meet production plan and dispatch deadline.
• Align with SCM on streamlining the production plan to minimize the stoppages and dye changes to achieve maximum machine utilization.
• Revise production schedules as per priorities as result of equipment failure or operating problems.
• Ensuring Raw Materials are available as per production plan to maintain continuity of production lines.
• Coordinate with warehouse team daily for material movement from shop floor and material movements in stipulated timelines.
• Responsible for different Mechanical/ Electrical/ Instrumentation Jobs carried out during shift hours. Also ensure safety of the job, job location and equipment involved before, during and after the job completion.
• Implement safety, Health and Environment system of the plant concerning man and equipment.
• Guide shop floor personnel to ensure compliance of BASF's statutory requirements, which also includes training of the subordinated regarding the safety aspects and handling of the critical monomers/ hazardous chemicals.
• Implement that discharge parameters of all the emissions in the plant are within the statutory limits and health and hygiene of the plant personnel is well maintained.
• Implement the PPE rules and Permit to work system at plant.
• Train the plant personnel on RCMS applicable to plant.
• Implement Process Safety and Environmental protection code as per BASF practice.
• Implement the documentation of Responsible care requirement on continual basis.
• To maintain the stock variance on monthly basis and report any discrepancies.
• Ensure PGM control and find and resolve differences for any variances on order basis.
• Performs the role as defined in On-site Emergency Plan to mitigate the emergencies.
• Have an Out of the Box thinking to resolve the issues and lead idea generation and implementation to have continual improvement on shop floor.
• Raise material purchase requisition as per consumables requirement to prevent stock out situations.
• Supporting in PPAP's and new product development activities by alignment with PD/Process department.
• Providing RCA and CAPA for customer/internal quality related concerns and monitoring and controlling COPQ.
• Maintain 5S Culture and continuously work upon improvement and upgradation to sustain 5S

2. Efficiency

• Achieving targeted efficiency in Production with focus on Quality by reducing Rework and Rejection.
• Monitoring and ensuring a stable Production process with attention to achieve Process capability.
• Maintain walkthroughs in production plant to ensure early diagnosis of abnormalities and initiate timely corrective actions and preventative practices.
• Review and analyse coating line KPIs and trigger action plan to improve on it.
• Ensuring regular checks on shopfloor documents and checksheets for regular up-dation.
• Lead and support in plant upgradations and improvements by supporting regional/internal project teams.
• Align closely with SCM/QC/QC/PD/WH/Admin to have error free operations and act as a common point of contact for specific shop floor requirements.

3. Operational Excellence

• Identify the scope of improvement in coating operation and initiate Op-Ex projects for productivity improvement, cost reduction and quality improvement.
• Process Improvement/modification are carried out within the agreed Capital Investment budget.
• Monitoring, improving, and reinforcing Clean and Safe Work environment by following the best practices of 3C & 5S.
• Support in COAT initiatives.
• Challenge old methods and processes and develop and bring into system more effective methods and processes to make it more effective.

4. Quality Management System

• Update knowledge QMS, OHSAS and EMS through proper channel.
• Formulate, implement, and adhere to Quality Management Systems IATF 16949, ISO14001, OHSAS 18001 & 5-STAR requirements of Hyundai leading to Customer Satisfaction.
• Monitor process development and implement updated operating methods and procedures to ensure and improve product quality. Assist in customer and supplier audits.
• Regular alignment with QC/QA regarding customer specific requirements/new requirements supports.
• Train as an internal auditor and lead internal audits and compliances.

5. Human Resources & Leadership

• Supervise shifts' adherence to plant procedures and guidelines.
• Establish measures to keep and strengthen knowledge and capabilities of plant operators and shop floor working team.
• Organize/ provide coaching/feedback to all subordinates. Organize and perform instructing and training of new employees
• Prepare performance appraisals for all subordinates.
• Prepare monthly shift schedules of operators and ensuring adherence. Approve leaves and Overtime with proper accountabilities.
• Lead Skill matrix evaluation of operators and CL on timely basis including the shop floor people development plan.

Responsible Care / EHS Related Roles & Responsibilities

• 
  As the responsible person for Process Safety, he has responsibility of ensuring Safety to all the people working in the plant through continuously identifying the Near Misses & Hits and correcting them, to identify the potential hazards in the site and eliminating them, to carry out risk analysis for all the activities either based on activities or based on areas of operation, identify the high risk & medium risk activities / areas and take appropriate countermeasures for reducing the risk.
• Must support for 100% compliance by all people in the site for the PPE requirements.
• To ensure Permit System requirements are met fully.
• To support for the departmental Safety meetings to bring awareness of all people working in his department.

Minimum Education and Qualification Required for the Position

• 
  Education: B.E / B. Tech in Engineering in Mechanical/Chemical/Production.
• Working Experience: Minimum 8 Years
• Technical & Professional Knowledge: Knowledge of Automobile Industry