Job Title: Wafering WGRSummary
The Wafering Division is divided into three sections: Shaping, Sawing, and Wet & WINS.
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Shaping Section:
- Cropping
- Squaring
- Grinding & Inspection
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Sawing Section:
- Gluing
- Wire Sawing
- Wire Guide Roller (WGR)
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Wet & WINS:
- Precleaning
- Final Cleaning
- Wafer Inspection
In Shaping, monocrystalline ingot is cropped into segments and shaped into bricks. In Sawing, the bricks are cut into wafers. In Wet & WINS, the wafers are finally cleaned and inspected.
The Shift Engineer (Wafering Operation) will manage equipment status, personnel, consumables, and the overall status of the site in one of the subsections above. The role requires identifying and monitoring critical parameters, addressing factors that impact process control, yield, and throughput, providing direction and feedback during shift operation, scheduling employee shifts, assigning duties, and training and coaching new employees. Ensuring health and safety standards is essential.
Typical equipment handled includes: Croppers, Squarers, Grinders, Visual Inspection Machines, Gluing, Wire Sawing Machines, Cleaners, Wafering Inspection Machines, CNC Machines, etc.
In the long run, the person is expected to develop the capability to lead all three sections individually.
Important Note
As this is a startup plant, the person is expected to stretch beyond normal working hours (as and when required) to resolve teething issues related to startup and conduct debottlenecking, in order to stabilize the section as per the designed throughput.
The candidate should have strong leadership skills (particularly an ownership mindset), be a team player, and demonstrate values and behavior that maintain cordial relations with the shop floor team, cross-functional teams, and all internal stakeholders, in a high workload, typical chemical plant startup environment.
Demonstrate passion in leading startup of the 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 personally as and when the situation demands.
Able to handle large teams amicably and align the team towards operational goals of the Ingot & Wafer Business.
Take thorough training in Emergency Response Planning and develop capabilities of handling emergency situations such as large leakages, fire, explosions, gas releases, earthquakes, etc., thereby ensuring minimal or no damage to people, equipment, and environment.
Job Accountabilities (Duties and Responsibilities) Safety
- Zero LTC
- Issue work permits with 100% compliance for all engineering or non-routine tasks as per standard with proper job safety risk assessment attached to permit
- Special focus on line break, hot work, and confined space related jobs
- Zero tolerance for unsafe behavior
- Demonstrate and lead strict adherence to safety standards and compliance on shop floor
- Ensure operations as per Health, Safety, Environment, and Fire standards
- Take periodic Gemba rounds and control unsafe acts and unsafe conditions on shop floor
- Lead audits, visits, and documentation
Production
- Lead startup of section with a focus on zero safety incidents, zero quality incidents, zero incidents of wafering equipment shutdown
- 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 and 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 and achieve benchmark OEE
- Lead audits and visits
- Lead documentation
- Handover shift charge to reliever as per HOTO (Handover Takeover) guidelines
- Plan and ensure 100% availability of raw material, packing material, and consumables for the upcoming shift
Quality
- All operations/tasks as per documented and approved procedures
- Ensure input and output is as per approved quality specs
- Eliminate all sources of contamination through best shop floor discipline and engineering or administrative controls as 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 and improve yield of all equipment by demonstrating their design capabilities
Team / Manpower
- Develop the team in fundamental understanding of engineering knowledge of equipment in the section
- Handhold and coach the manpower on operational nuances of the section
Skills Required (Knowledge and Skills)
- Strong in MS Office package (Excel, Word, PPT, Teams, Outlook, etc.)
- Strong in implementing SOPs, Dos & Donts, risk assessments, standard operating conditions, Critical to Quality (CTQs) guidelines on shop floor
- Good written and verbal communication skills in Gujarati language (preferred)
- Good communication skills in English & Hindi (verbal & writing)
- Working knowledge of ISO 9001, 14001, 45001, 50001
- Added advantage: Minitab, Six Sigma, QC Tools, Kaizen, Statistical Process Control, TQM
