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Key Responsibilities and Required Skills for Unit Operations Assistant

💰 $40,000 - $65,000

ManufacturingOperationsEngineeringProcess Control

🎯 Role Definition

The Unit Operations Assistant supports day-to-day process and production activities on a manufacturing or process unit by assisting operators, monitoring process conditions, performing routine maintenance and sampling, and ensuring compliance with safety and quality procedures. This role is designed for hands-on contributors who are detail-oriented, safety-focused, and comfortable working with control systems (DCS/PLC/SCADA), standard operating procedures (SOPs), and basic laboratory sampling. Ideal for manufacturing, chemical, wastewater treatment, and pharmaceutical environments where consistent, safe production and regulatory compliance are critical.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Process Technician I / Operator Trainee
  • Maintenance Technician Apprentice
  • Laboratory Technician (sampling-focused)

Advancement To:

  • Process/Unit Operator
  • Senior Operations Technician
  • Shift Supervisor / Operations Team Lead

Lateral Moves:

  • Maintenance Technician (mechanical/electrical)
  • Quality Control / Quality Assurance Technician

Core Responsibilities

Primary Functions

  • Assist licensed or senior operators in the safe startup, shutdown, and steady-state operation of process units by physically operating valves, pumps, compressors, and other process equipment in accordance with written procedures and control room directions.
  • Continuously monitor unit process parameters (temperature, pressure, flow, level, pH, conductivity) via distributed control systems (DCS), PLCs, or SCADA and respond to alarms or operator instructions to maintain product quality and process stability.
  • Perform routine process and environmental sampling (liquid/solids/gas) and conduct basic field tests (pH, conductivity, turbidity, temperature) following sampling SOPs and chain-of-custody procedures; deliver samples to lab when required.
  • Maintain accurate and timely unit logbooks, electronic shift records, batch records, and maintenance tags, documenting all operational activities, deviations, and corrective actions to support audits and traceability.
  • Execute routine preventive and predictive maintenance tasks under supervision (lubrication, belt/pump checks, filter changes, minor repairs, instrument calibration checks) and coordinate with maintenance for planned and emergency repairs.
  • Follow and enforce lockout/tagout (LOTO), confined space entry, hot work, and other safety procedures; participate in pre-job risk assessments and ensure PPE and safety permits are in place before work begins.
  • Assist with unit turnovers and handoffs between shifts, communicating outstanding actions, abnormal conditions, and status of ongoing work to ensure continuity of safe operations.
  • Perform routine cleaning and sanitation duties, including clean-in-place (CIP) or steam-in-place (SIP) operations per SOPs in food, beverage, pharma, or biotech facilities to prevent contamination and ensure product quality.
  • Support batch processing activities by preparing raw materials, measuring and transferring ingredients, assembling and reviewing batch documentation, and observing critical control points during batches.
  • Troubleshoot basic process upsets and mechanical issues (bearing noise, pump cavitation, seal leaks) using a structured troubleshooting approach; escalate complex issues to operations or maintenance leads.
  • Follow GMP, FDA, EPA, OSHA, and company-specific regulatory requirements and participate in internal and external inspections to demonstrate compliance and readiness.
  • Assist with inventory control for spares, chemicals, and consumables—receiving, labeling, storing, and rotating stock to minimize downtime and ensure safe storage of hazardous materials.
  • Operate and perform basic diagnostics on process instrumentation (flowmeters, pressure transmitters, level sensors, thermocouples) and report calibration drift or failures to instrumentation/automation teams.
  • Execute emergency response procedures including spill containment, emergency shutdowns, and first-response support during unit incidents while coordinating with safety and emergency teams.
  • Participate in root cause analysis for process deviations and non-conformances by collecting data, preserving evidence, and helping implement corrective and preventive actions (CAPA).
  • Assist with commissioning and decommissioning activities for new equipment installations, piping modifications, and unit upgrades, ensuring that pre-start checklists and validation requirements are completed.
  • Support continuous improvement and lean manufacturing initiatives by suggesting process improvements, participating in Kaizen events, and documenting small improvements that reduce waste or increase reliability.
  • Ensure accurate labeling and segregation of hazardous materials and waste streams and coordinate with environmental teams for proper disposal, recycling, or treatment in compliance with permits.
  • Use computerized maintenance management systems (CMMS) or enterprise resource planning (ERP) tools (e.g., SAP) to enter work requests, track maintenance histories, and close out completed work orders.
  • Conduct basic mechanical assists such as coupling alignment, pump re-primes, valve exercising, and cleaning strainers to keep units operating within acceptable parameters.
  • Support production changeovers by helping in equipment reconfiguration, flushing lines, ensuring correct material sequencing, and verifying that GMP cleaning and qualification steps are followed.
  • Participate in training programs for junior staff and act as a backup trainer on specific unit tasks or safety procedures, ensuring knowledge transfer and consistent operational practices.

Secondary Functions

  • Maintain housekeeping of work areas, tooling, and walkways to support 5S and facility safety objectives.
  • Support operations and engineering with routine data collection, process trending, and documentation required for troubleshooting and continuous improvement projects.
  • Help coordinate spare parts procurement and assist stores personnel with identifying critical long-lead items for the unit.
  • Participate in internal audits, process safety management (PSM) reviews, and safety observations; document findings and assist with follow-up actions.
  • Assist quality teams during in-process inspections and support corrective actions until items are closed.
  • Provide cross-functional support during plant outages, turnarounds, and planned maintenance windows by assisting maintenance crews and contractors.
  • Contribute to training material updates by providing practical, on-the-floor feedback to SOP and work instruction authors.
  • Act as a liaison between operations, maintenance, instrumentation, and lab teams to ensure smooth execution of daily tasks and projects.

Required Skills & Competencies

Hard Skills (Technical)

  • Distributed Control System (DCS) or SCADA operation and basic navigation for monitoring and acknowledging alarms.
  • Basic PLC familiarity (reading module statuses, understanding I/O points) and ability to report PLC faults to automation teams.
  • Process instrumentation awareness (pressure, temperature, level, flow) and ability to perform basic field checks and relay findings.
  • Hands-on experience with pumps, compressors, valves (manual and actuated), heat exchangers, and basic rotating equipment maintenance.
  • Sampling techniques, chain-of-custody, and familiarity with laboratory handoffs and in-process testing protocols.
  • Working knowledge of SOPs, GMP (Good Manufacturing Practices), HACCP (if food industry), ISO standards, and regulatory compliance basics.
  • Proficiency using computerized maintenance management systems (CMMS) and basic Microsoft Office (Excel for logs and trending).
  • Safe handling and storage of chemicals, including familiarity with SDS (safety data sheets), chemical compatibility, and PPE requirements.
  • Lockout/Tagout (LOTO), confined space entry, and other safe-work-permit practices.
  • Basic mechanical troubleshooting and use of hand tools, inline cleaning (CIP/SIP) procedures and startup/shutdown checklists.

Soft Skills

  • Strong verbal and written communication skills for clear handovers, incident reporting, and cross-functional collaboration.
  • Attention to detail and process discipline to follow SOPs, batch records, and quality requirements consistently.
  • Problem-solving orientation with the ability to troubleshoot under pressure and escalate appropriately.
  • Teamwork and collaboration—works effectively with operators, maintenance, engineers, and lab personnel.
  • Adaptability and willingness to work rotating shifts, overtime, and respond to off-shift emergencies as required.
  • Positive safety mindset with the ability to coach peers on safe work practices and identify hazards proactively.
  • Time management and ability to prioritize tasks in a fast-paced production environment.
  • Observational skills to identify anomalies early and prevent small issues from becoming operational incidents.
  • Continuous improvement mindset—actively suggests and participates in efficiency and reliability improvements.
  • Customer-service orientation when interacting with internal stakeholders such as production planners and quality teams.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED required; vocational certificate in process technology, industrial maintenance, or equivalent preferred.

Preferred Education:

  • Associate degree in Process Technology, Chemical Technology, Industrial Maintenance, or related technical field.
  • Certifications in process operations, OSHA safety, or industry-specific training (e.g., wastewater certification, forklift, HAZWOPER) are advantageous.

Relevant Fields of Study:

  • Process Technology / Chemical Technology
  • Mechanical or Electrical Maintenance Technology
  • Industrial Safety / Environmental Technology
  • Quality Assurance / Laboratory Science

Experience Requirements

Typical Experience Range: 0–3 years for entry/assistant level; 2–5 years recommended for facilities with complex processes.

Preferred:

  • 1–3 years of hands-on experience in a manufacturing, chemical, wastewater, pharmaceutical, or food & beverage process environment.
  • Demonstrated experience with DCS/SCADA monitoring, adherence to SOPs/GMP, routine sampling, and basic maintenance tasks.
  • Prior exposure to safety programs (LOTO, confined space, permit-to-work systems) and participation in continuous improvement activities is a plus.
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