Ineos Styrolution Hiring for Manager Mechanical Maintenance at Dahej, Gujarat, India Full Time

Job Description

SUCCEED. IN OUR EXPERIENCED TEAM.
INEOS Styrolution is the leading global styrenics supplier, with a focus on styrene monomer, polystyrene, ABS Standard and styrenic specialties. With world-class production facilities and more than 90 years of experience, INEOS Styrolution helps its customers succeed by offering solutions, designed to give them a competitive edge in their markets. At the same time, these innovative and sustainable best-in-class solutions help make the circular economy for styrenics a reality. The company provides styrenic applications for many everyday products across a broad range of industries, including automotive, electronics, household, construction, healthcare, packaging and toys/sports/leisure. In 2020, sales were at 4 billion euros. INEOS Styrolution employs approximately 3,600 people and operates 20 production sites in ten countries. A. Purpose/Role of the job /: Describe in 1 phrase what contribution the job is expected to make to the organization’s objectives Responsible for maintenance of all mechanical equipment of the plant in order to keep the assets in healthy condition, improve plant reliability and availability. Implement best operation & maintenance practices, PM/PdM maintenance to reduce breakdown through SAP implementation and spares management. Analyse the upset/failure and take corrective & preventive action for future to avoid recurrence of the problem and resolve chronic issues. Ensure that all activities of Mechanical and associated contractors are done in accordance with INEOS Styrolution SHE guidelines. Key member of site ISO 50000 implementation team. B. Environment/Context/Complexity of the job: Describe the most important internal and external factors influencing the job Internal:

• Compliance to INEOS Styrolution SHE guidelines.
• Compliance to quality standard ISO-9001 and Environment Management System (ISO-14001).
• Knowledge of techniques for efficient use of energy and plant operation.
• Compliance to INEOS Styrolution IGGN guidelines.

  External:

• Liaison with Statutory Authorities and timely compliance to Boilers, Gas, Pressure vessels and lifting tools testing & inspection.
• Dealing with contractors for effective and safe work at site.

  C. Responsibilities/Accountabilities of the job: Describe the main results expected from the job.

1. Key Result Areas: Incident free operations, Adherence to INEOS Styrolution SHE guidelines, Compliance of local regulations. Major Activities:

• Participate in regular safety training at site:
  • Safety rules and guidelines
  • Operating procedures
  • Incident sharing and learning
  • Permit to work and Risk Assessment, etc.
• Active support to the safety culture at site and work safely for incident free operation.
• Understand and follow annual SHE improvement plan for the site.
• Work in line with SHE KPIs and Targets set by management from time to time.
• Contribute to Behavior Based Safety (BBS) program at site.
  • Participate on training at site to take BBSO to next level of reporting.
• Support Site SHE committee to resolve safety issues and drive SHE performance.
• Be conscious that all incidents including Near Miss at site must be reported, investigated and action items must be tracked to closure.
  • Active use of KMS for incident reporting and investigation, MOC, action item tracking
  • Collaborate to track and close all SHE related action items from audit, plant walkthroughs.
• Support the Asset Manager, responsible for the overall integrity of the site.
  • Contribute to INEOS Styrolution Asset Care program
  • Take responsibility for maintaining the asset and integrity of the protective system.
• Follow site procedures aligned with INEOS Group Guidance Notes (IGGNs).
• Accountable for
  • Following and practicing INEOS 20 principles of Behavior Safety and Process Safety at site
  • Following and practicing Life Saving Rules at site
  • Safety of other Employees, Contractors, Visitors and partners at site
  • Following Permit to Work as per the site procedure
  • Following Management of Change (MOC) as per the site procedure.
• Responsible for
  • Participating in HAZOPs at site as per procedure
  • Tracking action items from HAZOP to closure.
• Work in compliance with all legal regulations.
  • Adherence to site licenses and permits.
• Participate on the INEOS Styrolution Sustainability program at site.
• Stop work whenever there is an unsafe condition and immediately inform the Shift Leader and/or Head of Department.
• Directly intervene with those in your working area not using PPE or not following INEOS Styrolution standards and procedures.
• Maintain the respective workplace in order and clean, as per best practices of housekeeping.

Outcome: Zero incident/accident in the plant with sustainability and safe operation.

• Key Result Areas: Maintenance of plant equipment

Major Activities:

• Safe and trouble free maintenance of all equipment installed in the plant.
• Execute Preventive and predictive maintenance of all equipment as per the schedule and maintenance procedures.
• Monitoring the efficiency of all equipment like HIPS, GPPS, Bagging machines, DM plant, Nitrogen Plant, Refrigeration plant, filtration plant, HTM heaters, Steam Boilers, cooling tower and implement measures for improvement.
• Ensure availability of updated documentation such as P&IDs, operation & service manuals, GA drawings, Piping drawings, stress analysis, fabrication drawings and SOPs/SMPs etc.
• Ensure latest documentation/P&ID set are available in designated areas and in good condition
• Ensure process safety inspection plan is prepared and executed in the plant as per the schedule.
• Ensure that all standby equipment are always available for operation. Repairs to be done immediately in case of any problem.

Outcome: Availability of plant equipment for smooth operation.

• Key Result Areas: Normal operation / Startup / Shutdown of equipment

Major Activities:

• Follow all SHE guidelines and work procedures during daily operation, startups and shutdown of equipment in consultation with production department.
• Ensure safe practices are followed during startup and shut down of equipment according to OEM recommendation and production requirement.
• Ensure equipment are operated within norms and plan for corrective measures in case of deviations.
• For shutdown proper planning should be done in advance with Time chart for the stop/start activity, spares requirement, manpower planning and other resources required.

Outcome: Perform safe and smooth operation of the plant / startup / shutdown

• Key Result Areas: Troubleshooting and co-ordination with other department for equipment maintenance.

Major Activities:

• Prepare preventive & predictive maintenance schedule and implement the same through SAP in

Co-ordination with production department.

• Pending PM/PdM to be tracked and completed within tolerance time limit
• Record history for preventive maintenance and breakdown maintenance.
• Root cause analysis of equipment to reduce breakdowns and implement recommended actions.
• Prompt action for attending the breakdown to restore the operation of GPPS/HIPS production.
• Ensure Zero leakages of any Utilities / Lubricants / Pump seals with effective monitoring and fixing plan.

Outcome: Reduction in downtime of equipment.

• Key Result Areas: Maintenance of Environmental Facilities

Major Activities:

• Maintenance of Environment facilities at site such as Waste water treatment plant etc. according to legal requirement.
• Prepare and implement preventive maintenance plan for these facilities.
• Ensure safe practices are followed during operation and maintenance.

Outcome: Improve Reliability of environmental facility

• Key Result Areas: Energy & Quality management and statutory compliances.

Major Activities:

• Prepare documentation and implement ISO 9001:2008 QMS & ISO 14001:2004 EMS systems.
• As a part of ISO 50000 leadership team, active participation and drive the energy management program at site.
• Corrective action to be taken on suggestion of internal or external auditor.
• As part of statutory requirement testing & Inspection of boiler, pressure vessel and lifting tools and tackles, testing and analysis of Thermic Fluid quarterly.

Outcome: Comply Statutory requirement, Energy management and Quality & Environment Management System

• Key Result Areas: Preventive Maintenance and spares management through SAP

Major Activities:

• Maintain spares for its requirement during preventive maintenance, breakdown and day to day routine maintenance work.
• To prepare PM plan and execute maintenance work through SAP-PM module.
• Prepare & updating plant Equipment list in SAP-PM with BOM of their spares.
• Updating maintenance Task list in SAP for PM of each equipment and AMC activities.
• Preparation, review & implementation of Predictive Maintenance (PdM) plan for the Mechanical/Utility equipment.
• Take corrective action for the abnormality shown in the vibration monitoring, Oil testing, thickness testing reports and arrange re-inspection for verification.
• Maintain minimum required inventory of critical spares in stores as per the defined list.
• Spares available in stores and in department should be checked and tested in advance and kept as ready to use to reduce equipment downtime for maintenance.

Outcome: Maintenance through SAP and Reduction in down time with proper planning of spares
D. Dimensions: Describe the most representative figures of the job (for example: number of staff, budget you’re responsible for, number of projects.)
Facts
Number or amount in €

Production Capacity ( HIPS/GPPS)
78 KTA

Pelletizers
2

Auto bagging machines
2

Steam Boilers
2 X 2 TPH each

HTM Heater
1 X 2.8 M kcal/h

N2 generation Plant
1 X 300 M3/H

Brine chillers
2 X 74 TR each

Air compressors
2 X 1200 M3/hr + 1 X 900 M3/hr

Cooling Tower
1 X 2000 TR

DMin water plant
160 M3/day

WWTP
215 KL/day
Supervision of staff: Give the number of people you supervise (“Direct” means that they report directly to you, “Indirect” means they report to someone who reports to you.)
Direct
Indirect
Total

1
5
6
E. Main contacts /Interfaces: What are the internal and external contacts you have, necessary for reaching your results?
Who
Frequency of contacts

My role in those contacts [1]

• Responsible
• Accountable
• Consulted
• Informed

Purpose of contacts

Utility
Daily
A,C,I
For operation and maintenance work

Production Shift Executive
Daily
C,I
For better coordination for smooth operation of plant

Maintenance (Mechanical / Instrument/ Electrical)
Daily
AC,I
To do the required job on time

QA
Daily
C,I
Quality of utility generated

SHE
Daily
A,C,I
Follow SHE guidelines effectively in the plant

HR/IR/SCM-P department
As and when required
C,I
To do the required job on time

Vendors/Contractors/Govt agency
As per plant requirement
C,I
To get the job done on time
F. Required profile:

Level of education & Knowledge:

• BE Mechanical in 1st division
• English, Hindi / Gujarati

Experience in general:

• Minimum 12 years of experience in operation & maintenance of Utility and other process equipment in a polymer or petrochemical industry.

Technical skills:

• Awareness about Safety, Work permit system, Risk Assessment and Tool Box talk.
• Knowledge of Operation & maintenance of Utility & plant equipment like Boiler, Thermic Fluid Heater, Refrigeration plant, Cooling tower, Air compressor, Nitrogen plant, pumps & blowers, agitators, gear boxes, mechanical seals, gear pumps , Pelletizers, Auto bagging machines etc.
• Energy management / auditing certificate/ skills.
• Knowledge of statutory requirement applicable for plant equipment such as IBR/Pressure Vessels/Licensing requirement etc.
• Working knowledge of SAP – PM/MM modules.
• Energy Management: Energy conservation measures, techniques and other cost saving methods.
• Knowledge of AutoCAD.

Competencies, Behavioral skills: (acc. to competency profile and required level of descriptions)

• Positive attitude towards safety norms, work procedures & alertness for self and others.
• Responsible and reliable.
• Communication skill – verbal & written in English, Hindi/Gujarati.
• Team player with One team concept and able to lead the team.
• Analytical skill for solving repeated & chronic problems.

Legal Training Requirements

• Under the provision (111-A) of the Factories Act 1948, reading with Gujarat Factory Rules 1963 about General Health & Safety, Emergency response, handling of hazardous substance

Job Requirements:

• Must be able to climb ladders and stairs
• Walking/standing up to 8 hours a day
• Must be able to lift upto 25 kg of weight
• Must be able to work in confined spaces.
• Willing to work in shifts as and when required.

G. Performance indicators: Describe the criteria allowing to measure to what extent the results are achieved – related to the accountabilities

• Asset Care program- Compliance of all standards in plant
• Equipment availability.
• Compliance of INEOS Styrolution SHE Standards for direct workers and contractors on site.
• Compliance of all legal requirements and IGGNs on time.
• Monitoring of Operation / Maintenance related KPI’s of Utility such as equipment efficiency, downtime, specific consumption and maintenance cost.
• PM compliance
• PdM compliance
• RCA prepared and compliance of recommendations

If you require further information please contact Ruchi Sharma. Of course, your application will be treated confidentially. Human Resources ruchi.sharma@ineos.com

Job Details

• Location Dahej, India
• Discipline Operations
• Type Permanent
• Business INEOS Styrolution
• Posted 15 December 2021
• Closing Date 28 February 2022
• Requisition ID 8127