Key Responsibilities and Required Skills for Head Operator

🎯 Role Definition

This role requires a highly skilled and safety-oriented Head Operator to lead our production team and oversee plant operations during their shift. In this pivotal role, you will act as the on-site operational authority, responsible for ensuring the safe, efficient, and continuous operation of our state-of-the-art facility. The ideal candidate is a proactive problem-solver with extensive hands-on experience in a process-driven environment and a proven ability to lead and mentor a team of operators. You will be instrumental in maintaining production targets, upholding stringent quality and safety standards, and driving continuous improvement initiatives on the floor. If you thrive under pressure and have a passion for operational excellence, we invite you to apply for this critical leadership position.

📈 Career Progression

Typical CareerPath

Entry Point From:

Senior Operator
Control Room Operator
Lead Process Technician

Advancement To:

Operations Shift Supervisor
Production Manager
Plant Superintendent

Lateral Moves:

Process Safety Specialist
Maintenance Coordinator

Core Responsibilities

Primary Functions

Direct and supervise a team of control room and field operators, ensuring all tasks are performed safely and efficiently according to standard operating procedures (SOPs).
Monitor and control all plant processes and utility systems using the Distributed Control System (DCS) and SCADA to maintain operational stability and product quality.
Serve as the primary point of contact for all operational activities during the shift, making critical real-time decisions to address process upsets and emergencies.
Execute and oversee plant start-up, shutdown, and emergency shutdown procedures in a safe and controlled manner.
Enforce all Environmental, Health, and Safety (EHS) policies, including Lockout/Tagout (LOTO), confined space entry, and hot work permit procedures.
Lead the initial response to any plant emergencies, incidents, or environmental spills, activating the emergency response plan and coordinating with emergency services.
Conduct comprehensive shift turnover meetings, communicating critical operational status, ongoing issues, and priorities to the incoming shift team.
Troubleshoot complex process, equipment, and quality control issues, collaborating with maintenance, engineering, and lab personnel to implement effective solutions.
Train, mentor, and develop junior operators, providing coaching on SOPs, safety protocols, and advanced troubleshooting techniques to build team competency.
Manage operator schedules, assign daily work tasks, and conduct performance evaluations to foster a high-performance work culture.
Authorize and issue safe work permits, ensuring all prerequisite safety checks and isolations are completed and verified before work commences.
Maintain meticulous and accurate operational records, including shift logs, production data, environmental reports, and incident investigations.
Perform regular field rounds and inspections to verify equipment health, process conditions, and adherence to housekeeping standards.
Coordinate with the maintenance department to prioritize and schedule repair work, ensuring minimal disruption to production schedules.
uninterrupted
Collect and analyze process samples to ensure product specifications are met, making necessary adjustments to the process to correct any deviations.
Identify and champion opportunities for process optimization, cost reduction, and efficiency improvements through continuous improvement methodologies.
Lead and participate in Root Cause Analysis (RCA) for safety incidents, environmental events, and significant production losses.
Assist in the commissioning and start-up of new equipment and process units, including reviewing P&IDs and developing new operating procedures.
Manage inventories of raw materials, chemicals, and intermediate products, coordinating with logistics to ensure an uninterrupted supply chain for operations.
Ensure compliance with all regulatory requirements (e.g., OSHA, EPA) and internal company standards during all operational activities.
Conduct daily safety briefings (toolbox talks) to reinforce safety culture and communicate any immediate hazards or procedural changes.
Oversee the isolation and preparation of equipment for maintenance activities, ensuring it is safe for personnel to work on.

Secondary Functions

Participate actively in site safety committees and process hazard analysis (PHA) reviews.
Assist in the development, review, and updating of Standard Operating Procedures (SOPs).
Support plant-wide initiatives and capital projects by providing operational insight and expertise.
Act as a subject matter expert during internal and external audits.

Required Skills & Competencies

Hard Skills (Technical)

Proficiency with Distributed Control Systems (DCS), SCADA, and/or PLC interfaces.
In-depth knowledge of plant-specific processes (e.g., chemical reactions, distillation, purification, power generation).
Strong understanding of Process Safety Management (PSM) and EHS regulations.
Expertise in safe work practices, including Lockout/Tagout (LOTO), permit-to-work systems, and confined space entry.
Ability to read and interpret technical diagrams, including Piping & Instrumentation Diagrams (P&IDs) and process flow diagrams (PFDs).
First-line troubleshooting skills for mechanical and process equipment (pumps, compressors, valves, etc.).
Emergency response and incident command training.

Soft Skills

Exceptional leadership and team management abilities.
Clear and concise verbal and written communication skills.
Strong analytical and critical thinking skills for effective problem-solving.
Calm and decisive decision-making, especially under high-pressure situations.
High level of attention to detail and procedural discipline.
Collaborative mindset with the ability to work effectively across different departments (Maintenance, Engineering, etc.).
An unwavering commitment to a safety-first culture.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.
Technical certification or diploma in a relevant field.

Preferred Education:

Associate's or Bachelor's degree in a technical or engineering discipline.

Relevant Fields of Study:

Process Technology
Chemical Engineering
Industrial Technology
Mechanical Engineering

Experience Requirements

Typical Experience Range: 5-10 years of progressive experience in a plant, manufacturing, or industrial operations environment.

Preferred: 2+ years of experience in a lead operator, supervisory, or senior-level role is highly desirable. Experience in a unionized environment may be required.