:

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.

- 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.
- 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.
- 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.
- 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.




- 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.
- 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.
- Solid 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.

📌 Senior Executive / Assistant Manager - Production (Bharuch)
🏢 SDP HR Solution
📍 Bharuch