FLO Process

Job Purpose

The role is focused on planning, organizing, and allocating resources so the plant can deliver the required quantity and quality of VSF. This is to be achieved through effective training, production tools, and sound operating methods.

Job Context

The spinning department manufactures VSF by regenerating cellulose from viscose through a spin bath and then applying a sequence of treatments such as washing, de-sulphurizing, bleaching, acid washing, and finishing before drying and baling for dispatch. The department produces multiple VSF variants to suit customer needs across cotton, polyester, acrylic, and 100% viscose yarn applications. The full spinning-to-baling flow runs as one continuous line with more than 1,500 rotating components. The work environment includes corrosive gases, acid-based liquids, and several other chemicals.

Major Challenges

• Water usage in the process is high, which becomes especially challenging during poor monsoon seasons.
• Running maintenance, rehabilitation, and technology upgrade activities in an operating plant while continuing to protect production, quality, safety, and environmental standards is a key challenge.
• There may be pushback from collective bargaining groups when technological improvements are introduced.

Key Result Areas

Production Planning and Control: Support production risk assessment and mitigation. Track schedules through daily reviews, identify process improvements, contribute to new product development, support customer service, ensure output matches quality and customer requirements, define manpower/material/equipment needs, resolve issues quickly, and escalate unresolved matters. Also handle shade matching in dyed fibre and analyze downtime using root-cause methods to reduce impact on cost, quality, and delivery.

Safety and Environment: Train employees and contractors as needed to ensure awareness of process safety standards and local safety requirements, including PSM/RMP programs. Support plants in major-risk Process Hazards Analyses using PHA methods, and contribute to process safety event investigations and root-cause analysis. Follow up corrective actions with site management when broader business issues are identified.

Change Management: Support problem-solving teams at the workplace so that projects are handled collaboratively and team performance improves.

Customer Centricity: Manage customer complaints in coordination with CTS and help ensure quantity and quality expectations are met.

People Management: Build a workplace environment where people issues can be discussed openly, help identify training needs with HR support, encourage recognition-driven behavior, and promote safety and environmental awareness through regular training where required.

Additional Information

The role operates in a plant setting where chemical exposure, continuous processes, and equipment reliability are important considerations. Any production optimization must be balanced with safety, environmental care, and workforce alignment during change initiatives.