Fertilizer Granulation Process Operator

The Mundy Companies•Freeport, TX

6d•$30•Onsite

About The Position

The Fertilizer Granulation Process Operator is responsible for safely and efficiently operating an automated fertilizer granulation process to produce consistent, high-quality fertilizer products. This position requires a highly detail-oriented individual who can continuously monitor critical process and quality measurements, make appropriate operating adjustments, identify potential problems before they impact production, and maintain equipment within established operating parameters. The successful candidate will have strong mechanical aptitude, good troubleshooting skills, and the ability to work independently with limited supervision. This individual must be disciplined, dependable, and accountable for achieving established production, quality, efficiency, and downtime Key Performance Indicators (KPIs). The Granulation Process Operator is expected to take ownership of the process from start-up through shutdown and ensure that production targets are achieved without sacrificing product quality or safety.

Requirements

High school diploma or equivalent preferred.
Previous experience in manufacturing, chemical processing, fertilizer production, or a related environment preferred.
Experience operating automated production equipment is highly desirable.
Strong mechanical aptitude and ability to troubleshoot industrial equipment.
Ability to understand and follow detailed operating procedures.
Ability to read and understand gauges, instrumentation, process screens, production reports, and quality measurements.
Basic computer skills and ability to operate computerized control systems.
Ability to perform basic mathematical calculations and understand production measurements.
Ability to work independently with limited direct supervision.
Ability to recognize process problems and respond appropriately.
Strong attention to detail and commitment to product quality.
Willingness to work in an industrial manufacturing environment.

Nice To Haves

Previous experience in manufacturing, chemical processing, fertilizer production, or a related environment.
Experience operating automated production equipment.

Responsibilities

Operate and monitor an automated fertilizer granulation system in accordance with established operating procedures.
Start, operate, adjust, and shut down granulation equipment safely and efficiently.
Continuously monitor process conditions through control systems, instrumentation, gauges, and physical observation.
Maintain the granulation process within established operating parameters to maximize production rates and product consistency.
Make timely process adjustments based on raw material conditions, equipment performance, product quality, and production requirements.
Monitor material flow, temperatures, moisture levels, pressures, speeds, feed rates, and other critical process measurements.
Maintain consistent product size, shape, density, moisture, and other established Critical-to-Quality (CTQ) characteristics.
Recognize process deviations and take corrective action before they result in off-specification product or significant production losses.
Follow established recipes, formulations, production schedules, and batch requirements accurately.
Maintain accurate production records, process logs, quality measurements, downtime records, and equipment observations.
Conduct required in-process quality checks at established intervals.
Monitor and document critical-to-quality measurements throughout the production process.
Identify trends or changes in product quality and make appropriate process adjustments.
Communicate quality concerns immediately to supervision and/or Quality personnel.
Prevent off-specification material by maintaining close attention to process conditions and product characteristics.
Properly segregate and identify non-conforming product when required.
Maintain a strong understanding of how changes in raw materials and process conditions affect finished fertilizer quality.
Use mechanical aptitude and basic troubleshooting skills to identify the cause of equipment and process problems.
Troubleshoot issues involving conveyors, feeders, pumps, motors, valves, screens, granulators, dryers, coolers, dust collection systems, and other production equipment.
Identify unusual sounds, vibrations, temperatures, material flow, equipment behavior, or other indications of developing problems.
Perform basic operator-level adjustments, cleaning, inspections, and minor corrective actions when authorized.
Work closely with Maintenance personnel to communicate equipment problems and provide useful troubleshooting information.
Assist Maintenance with troubleshooting and repairs when appropriate.
Identify recurring equipment problems and communicate opportunities for preventative maintenance or process improvement.
Minimize unnecessary equipment downtime by responding quickly and appropriately to operating issues.
Take personal responsibility for achieving daily production and efficiency targets.
Operate the process in a manner that maximizes production volume while maintaining safety and product quality.
Monitor key performance indicators including, as applicable: Production tons per hour, Total production volume, Equipment uptime, Unplanned downtime, Product quality, Product yield, Material loss, Energy efficiency, Rework and off-specification product, Changeover and startup efficiency.
Understand how operator decisions affect production rates, operating costs, quality, and overall plant performance.
Maintain a disciplined approach to operating procedures and production targets, even when working independently.
Continuously look for opportunities to improve throughput, reduce downtime, minimize waste, and improve process consistency.
Follow all company safety policies, procedures, and OSHA requirements.
Properly use required Personal Protective Equipment (PPE).
Maintain awareness of moving equipment, pinch points, rotating machinery, elevated temperatures, dust, chemicals, and other process hazards.
Follow Lockout/Tagout (LOTO) procedures when required.
Maintain a clean, orderly, and safe work area.
Perform routine operator inspections of equipment and work areas.
Immediately report unsafe conditions, equipment hazards, spills, leaks, or other safety concerns.
Participate in safety meetings, training, inspections, and continuous improvement initiatives.
Maintain accurate and timely production and process documentation.
Communicate equipment issues, quality concerns, process deviations, and production challenges to the appropriate personnel.
Provide clear shift-to-shift communication regarding equipment condition, production status, process settings, and outstanding issues.
Notify supervision of significant deviations from production or quality targets.
Maintain professional and productive communication with Maintenance, Quality, Warehouse, Shipping, and Production personnel.