Silicon Preparation Unit (SPU)
consists of two sections: Recycle Silicon Section (RSS) & Pre-Growth Section (PGS).
The purpose of Recycle Silicon Section is to recycle the silicon generated in-process.
The purpose of Pre-Growth Section is to prepare the Master Dopant, prepare Crucibles for Growing Section, and prepare Charging Hoppers for Growing Section.
Silicon Recycle Section has two subsections: Crushing & Cleaning.
Pre-growth Section has two subsections: Crucible Charge Dopant Management & Hopper Charging.
The typical nature of operations to be managed in SPU includes:
- Manpower Management (Full Time Employee & Temps)
- Manual / Semi Auto / Auto Operations
- Material Handling (Poly Silicon, Recycle Silicon, Crucibles, Crushers, Wet & Dry Cleaners of Silicon, ASRS (automated storage and retrieval system), MES (Manufacturing Execution System), Weighing, Technical Calculations of Dopant, Conveyors, Pumps, Drive Trains, Utilities, etc.)
The Shift Engineer will be placed either in Recycle Silicon Section or in Pre-Growth Section. In the long run, it is expected that the person grooms themselves for leading shifts of both sections.

Important Notes

Since it is a start-up plant, it is expected from the person to stretch beyond normal working hours (as and when required), to resolve teething issues related to start-up, and perform troubleshooting.
Person should have strong leadership skills (particularly ownership mindset), be a team player, and demonstrate appropriate values and behavior, thereby maintaining cordial relations with the shop floor team, cross-functional teams, and all internal stakeholders, in a high workload typical chemical plant start-up environment.
Demonstrate passion in leading start-up of section with a focus on zero safety incidents.
Lead from the front (hands-on knowledge) by working directly on the shop floor with reportees, demonstrating by operating the equipment.
Able to handle large size teams amicably, and able to align the team towards operational goals of Ingot & Wafer Business.
Take thorough training in Emergency Response Planning and develop capabilities of handling emergency situations such as big leakage, fire, explosion, gas release, earthquake, etc., thereby ensuring minimal damage to people, equipment, and environment.

Job Accountabilities (Duties and Responsibilities)
Safety

Zero LTC.
Accept work permits (from operations side) with 100% compliance for all engineering or non-routine tasks as per standards with proper job safety risk assessment attached to permit.
Special focus on line break, hot work, confined space related jobs.
Zero tolerance for unsafe behaviour.
Demonstrate & lead strict adherence to safety standards & safety compliance on shop floor.
Ensure operations as per Health, Safety, Environment, & Fire standards.
Take periodic Gemba rounds, and control unsafe acts & unsafe conditions on shop floor.
Lead audits, visits, & documentation.

Production

Lead start-up of section with a focus on zero safety incidents, zero quality incidents, zero incidents of grower stoppage (due to lack of availability of quality polysilicon).
Develop a process/system-based culture in managing operations.
Ensure output as per production plan.
Achieve best inventory accuracy for the section (physical stock vs. system stock).
Ensure 100% posting of batches & 100% consumption of material through MES & ERP systems.
Ensure 5S on shop floor.
Release periodic production related reports as per governance systems.
Participate in periodic plant review meetings.
Lead & achieve benchmark OEE.
Lead audits & visits.
Lead documentation.
Handover of shift charge to reliever as per HOTO (Handover Takeover) guidelines. Plan & ensure 100% availability of raw material, packing material & consumables for upcoming shift.

Quality

All operations/tasks as per documented & approved procedures.
Ensure input & output is as per approved quality specs.
Eliminate all sources of contamination by best shop floor discipline & best engineering or administrative controls as and where applicable.
Ensure operations are performed as per standard operating conditions (within aim +/- control limits).
Provide engineering solutions through data analysis to support quality assurance, customer complaint evaluations, process management, and problem troubleshooting.

Cost

Eliminate losses & improve yield of all equipment of setup by demonstrating their design capabilities.

Team / Manpower

Develop down the line team in the fundamental understanding of engineering knowledge of equipment in section.
Handhold & coach the manpower on operational nuances of section.

Skills Required (Knowledge and Skills)

Strong in MS Office package (Excel, Word, PPT, Teams, Outlook, etc.).
Strong in implementing SOPs, do's & don'ts, risk assessments, standard operating conditions, critical to quality (CTQs) guidelines on shop floor.
Good written and verbal communication skills in Gujarati language are an advantage.
Good in English & Hindi communication (verbal & writing).
Added advantage: Minitab, Six Sigma, QC Tools, Kaizen, Statistical Process Control, TQM, ISO 9001, 14001, 45001, 50001.

Key Attributes (Experience and Qualifications)

Experience:
2 to 12 years.
Preference:
- Exposure of working in a large metal plant.
- Experience working with a team of 25+ people is desirable.
- Should be aware of charging of metals, handling of metal pieces in large volume.
Qualification:
BE Engineering in Mechanical, Production, Chemical.
Industry:
Metal melting, foundries.

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