Reuse Polymer Executive/Waste Management (Reuse Polymers)

RP Plant Executive

Department: Recycling / Waste Management
Location: RP Plant
Reporting To: GM RP Plant/Stores

1. Job Purpose
To manage the day-to-day operations of the RP Plant and ensure efficient conversion of plastic waste into recycled product, achieving targeted production, yield, quality, cost and stock accuracy while maintaining safe and disciplined plant operations.
2. Key Responsibilities
A. Waste Inward & Material Management
* Receive and verify waste received from various units/vendors.
* Ensure proper weighing and documentation of all inward material.
* Maintain unit-wise and vendor-wise waste inward records.
* Ensure proper segregation of white, colour and other waste categories.
* Ensure waste is stored systematically in designated locations.
* Monitor ageing and non-moving waste stocks.
B. RP Production Operations
* Plan daily production based on available waste stock and production requirements.
* Ensure achievement of daily/monthly RP production targets.
* Monitor machine performance, process parameters and material flow.
* Track input waste vs. RP output, process loss and yield.
* Identify reasons for low yield and take corrective action.
* Work towards improving plant capacity and achieving targeted daily output.
* Ensure production is carried out as per SOP and quality requirements.
C. Yield & Waste Control
* Prepare daily yield analysis.
* Monitor:
* Waste Inward
* RP Production
* Process Loss
* Recovery %
* Machine Utilisation
* Rejection / Quality Loss
* Identify abnormal losses and immediately escalate deviations.
* Drive continuous improvement to reduce process losses and improve recovery.
D. Manpower Management
* Plan and allocate manpower for daily operations.
* Monitor attendance, productivity and discipline.
* Ensure operators follow SOPs and safe working practices.
* Train employees on segregation, handling, machine operation and housekeeping.
* Monitor labour productivity and take corrective action where required.
E. Maintenance Coordination
* Coordinate with the Maintenance Department for preventive maintenance.
* Ensure machine breakdowns are reported immediately.
* Track pending maintenance issues and follow up until closure.
* Monitor critical equipment such as cutters, sensors, screens, conveyors, motors and other RP plant equipment.
* Minimise machine downtime and improve equipment utilisation.
F. Stock & Reconciliation
* Maintain accurate physical and book stock of waste and RP.
* Conduct regular physical stock verification.
* Prepare daily/weekly/monthly stock reconciliation.
* Track waste sent to external RP vendors and material received back.
* Maintain vendor-wise reconciliation and identify shortages/excesses.
* Ensure proper documentation for all inward, outward, production and closing stocks.
G. Vendor & Logistics Coordination
* Coordinate with external RP/waste-processing vendors.
* Plan waste dispatches based on available stock and processing capacity.
* Monitor vendor stock and processing status.
* Coordinate with logistics for timely movement of waste and RP.
* Verify quantity and documentation for all vendor movements
H. Quality Control
* Ensure proper segregation and quality of input waste.
* Monitor quality of RP produced.
* Identify contamination, colour mixing and other quality issues.
* Coordinate with Quality and Production teams for corrective actions.
* Ensure only approved-quality RP is released for further use.
I. Safety, Housekeeping & Compliance
* Ensure strict adherence to plant safety procedures and PPE requirements.
* Maintain 5S/housekeeping standards.
* Ensure waste is stored only in designated areas.
* Prevent accumulation of waste on shop floors.
* Report unsafe conditions and incidents immediately.
* Ensure compliance with company SOPs and applicable environmental requirements.
J. MIS & Reporting
Prepare and submit:
* Daily Waste Inward Report
* Daily RP Production Report
* Daily Yield Report
* Machine Downtime Report
* Waste Stock Report
* Vendor Stock/Reconciliation Report
* Weekly Performance Report
* Monthly RP Plant MIS
* Production vs. Target Report
* Loss / Variance Analysis

3. Key Performance Indicators (KPIs)

* Daily/monthly RP production achievement
* Recovery / yield %
* Waste processing capacity utilisation
* Process loss %
* Machine uptime / downtime
* Waste stock accuracy
* Vendor reconciliation accuracy
* Quality rejection %
* Manpower productivity
* Cost per MT of RP production
* Safety compliance
* 5S / housekeeping score

4. Candidate Profile
Qualification: Diploma / Degree in Mechanical, Production, Plastics, Polymer, Operations or related field.
Experience: 37 years in recycling, plastic processing, FIBC/PP industry, production or waste management operations.
Required Skills
* Good understanding of plastic waste and recycling processes
* Strong Excel and MIS skills
* Good knowledge of production and yield calculations
* Stock reconciliation and inventory control
* Manpower handling
* Vendor coordination
* Basic maintenance understanding
* Strong analytical and problem-solving ability
* Good communication and leadership skills

5. Ideal Candidate

The candidate should be a hands-on plant executive who can independently manage daily RP plant activities, control waste movement, improve yield, maintain accurate stock records and coordinate effectively with Production, Maintenance, Quality, Stores, Logistics and external vendors.

Primary Objective:
Process maximum waste into quality RP with minimum loss, maximum yield and 100% stock accuracy.