Senior Manager – Safety

Purpose/Objective

The Senior Manager – Process Safety will be responsible for strengthening Process Safety Management governance across the Copper Manufacturing Complex and enabling safe, reliable, and compliant plant operations through structured risk management, assurance, and capability-building interventions.
The role will drive identification, assessment, mitigation, and monitoring of process safety risks across smelting, refining, utilities, acid plant, oxygen plant, PMR, and downstream operations.
The incumbent will work closely with operations, maintenance, projects, and SHE teams to institutionalize robust PSM practices, improve process safety performance, and support a Zero Harm workplace.

Key Responsibilities of Role

A.
Process Safety Management - Lead implementation and governance of the Process Safety Management (PSM) framework across plant operations.
- Conduct and facilitate HAZOP, HAZID, QRA, Bow-Tie Analysis, Layer of Protection Analysis (LOPA), and Process Risk Assessments.
- Review and monitor critical process safety barriers, safeguards, and control measures.
- Ensure compliance with applicable safety regulations, OISD standards, Factories Act requirements, and company SHE guidelines.
- Participate in design reviews, Management of Change (MOC), Pre-Start-up Safety Reviews (PSSR), and safety integrity assessments.
- Track and monitor leading and lagging process safety KPIs.
- Lead incident investigations related to process safety events and ensure timely closure of corrective and preventive actions.
- Develop and maintain processes safety documentation, manuals, and critical operating procedures.
B.
Safety Training & Capability Building - Guide safety capability-building interventions for employees, contractors, apprentices, and visitors, with specific focus on process safety-critical roles.
- Define annual process safety and safety training priorities aligned to statutory, operational, and risk-based requirements.
- Ensure coverage of Process Safety Awareness, Permit-to-Work, LOTOTO, Emergency Response, Confined Space, Work-at-Height, Contractor Safety, and critical risk training programs.
- Assess training effectiveness through competency assessments, practical demonstrations, audits, and behavioral observations.
- Establish competency matrices for process safety-critical and high-risk operational roles.
- Drive learning campaigns during National Safety Day, Fire Service Week, Road Safety Week, and other SHE initiatives.
- Promote digital learning and blended learning solutions through e-learning platforms and safety training modules.
C.
Risk Management & Compliance - Lead periodic process safety audits, gap assessments, and compliance reviews across operating areas.
- Monitor implementation of audit observations and closure of identified gaps.
- Ensure safety critical equipment inspections and testing schedules are adhered to.
- Support statutory inspections and interactions with government authorities and third-party auditors.
- Prepare and present process safety performance dashboards, audit status, and risk mitigation updates for management review.
D.
Emergency Preparedness & Safety Culture - Support process safety inputs for emergency response plans, onsite emergency plans, and scenario-based mock drills.
- Coordinate emergency preparedness training across plant functions.
- Drive behavioral safety initiatives and safety culture transformation programs.
- Facilitate contractor safety governance and safety awareness campaigns.
- Promote reporting and closure of Near Misses, Unsafe Conditions, and Unsafe Acts.
E.
Digitalization & Continuous Improvement - Drive digitization initiatives related to process safety observations, audits, action tracking, critical barrier monitoring, competency management, and training records.
- Develop dashboards and analytics for process safety performance monitoring.
- Benchmark global best practices and recommend improvements to enhance plant safety performance.

Technical Competencies

Process Safety Management,HAZOP HAZID LOPA QRA,Risk Assessment and Incident Investigation,Management of Change MOC and PSSR,Process Safety Competency Development,Emergency Response and Crisis Management

Qualifications and Experience

- B.
E.
/B.
Tech in Chemical, Mechanical, Metallurgical, Industrial Safety, Fire & Safety, or related discipline - PG Diploma in Industrial Safety (Preferred).
- Over 12 years of experience in Process Safety, Industrial Safety, Fire & Safety, or HSE in metals, mining, petrochemical, refinery, chemical, or heavy manufacturing industries.
- Minimum 5 years of hands-on exposure to Process Safety Management, risk studies, audits, incident investigation, and safety assurance systems.