Unit Operations Specialist — Key Responsibilities & Required Skills

🎯 Role Definition

The Unit Operations Specialist is a hands-on operations professional responsible for the safe, efficient, and compliant operation of a process unit or group of equipment within a manufacturing, chemical, biotech, or refining environment. This role combines process monitoring and control, start-up/shutdown execution, preventive maintenance coordination, incident investigation, quality and regulatory compliance (including GMP/FDA/OSHA), and continuous improvement initiatives. The specialist acts as a technical resource for operators, maintenance, and engineering teams to maximize throughput, minimize waste, and maintain product quality while ensuring employee safety and environmental compliance.

📈 Career Progression

Typical Career Path

Entry Point From:

Process Operator / Senior Operator
Chemical Technician / Laboratory Technician
Maintenance Technician with process exposure

Advancement To:

Unit Operations Supervisor / Shift Lead
Process Engineer / Senior Process Technician
Operations Manager / Manufacturing Manager

Lateral Moves:

Process Safety Specialist
Quality Assurance / Quality Control Technician
Reliability Engineer / Maintenance Planner

Core Responsibilities

Primary Functions

Operate and monitor unit processes (reactors, distillation columns, evaporators, filtration systems, heat exchangers, pumps and compressors) using DCS/SCADA/PLC systems to maintain production targets, quality specifications, and safety limits.
Execute safe start-ups, shutdowns, and transitions of production units according to approved procedures (SOPs), including cold/hot starts, purges, and emergency shutdowns, minimizing emissions and product loss.
Maintain and update batch records, production logs, shift reports, and electronic data capture systems accurately and on-time to support traceability, audits, and regulatory requirements (GMP/FDA).
Conduct real-time process troubleshooting and root cause analysis for process upsets, abnormal conditions, instrumentation faults, and quality deviations; implement corrective actions and notify engineering when needed.
Perform routine and preventive maintenance tasks, coordinate with maintenance planners, and supervise technicians during repairs to ensure minimal downtime and adherence to lock-out/tag-out (LOTO) procedures.
Enforce site safety programs, participate in safety meetings and toolbox talks, complete risk assessments and permit-to-work processes, and ensure compliance with OSHA, HAZWOPER, and site-specific process safety management (PSM) standards.
Sample process streams and perform on-site analytical tests (pH, conductivity, density, turbidity, titration, chromatography checks) following sampling SOPs to verify product quality and process stability.
Implement and support continuous improvement projects (Lean, Kaizen, Six Sigma) to improve yield, reduce cycle time, lower waste, and optimize utilities, often in partnership with process engineering and quality teams.
Calibrate and verify field instrumentation and control loops, escalate calibration or instrumentation issues, and confirm alarms and interlocks are functioning per safety instrumented system (SIS) requirements.
Maintain inventory of critical chemicals, catalysts, and spare parts for the unit; place orders, monitor shelf life, and manage proper labeling, storage, and handling of hazardous materials.
Lead and participate in formal shift handovers, ensuring thorough communication of operational status, outstanding actions, and safety concerns to incoming personnel.
Support environmental compliance by monitoring emissions, managing effluent and waste handling procedures, completing environmental logs, and responding to environmental incidents.
Train, mentor, and certify operators on unit procedures, safe work practices, troubleshooting techniques, and emergency response protocols to build operational capability and knowledge retention.
Execute planned production schedules and minor process adjustments to meet customer specifications and maximize throughput while minimizing off-spec production and rework.
Participate in pre-startup safety reviews (PSSR), hazard and operability (HAZOP) studies, and change management reviews to ensure procedural and technical readiness for modifications and project work.
Investigate non-conformances and customer complaints related to unit production; prepare technical incident reports, support CAPA (Corrective and Preventive Actions), and track resolution status until closure.
Collaborate daily with process engineering to test and implement process improvements, validate control strategies, analyze process data (trending) and implement tuning recommendations for PID loops.
Supervise contract technicians and external service providers working on the unit, ensuring compliance with site safety rules, permits, and quality expectations.
Maintain a strong focus on workplace housekeeping, 5S principles, and documented procedures to support a safe production environment and regulatory readiness.
Assist with cost control initiatives for utility usage, energy efficiency, and chemical consumption by collecting operational metrics and driving reduction projects.
Respond to and manage unit-level emergencies, coordinate evacuation or incident containment, and prepare incident summaries for management and regulatory reporting.

Secondary Functions

Support process data analytics by collecting process and performance metrics to enable long-term trend analysis and predictive maintenance initiatives.
Participate in cross-functional teams (quality, maintenance, environmental, procurement) to improve supply chain continuity and resolve operational bottlenecks.
Contribute to the development and continuous improvement of operational procedures, SOPs, and training materials to ensure clarity, compliance, and practical operability.
Assist engineering during pilot runs, commissioning activities, and scale-up studies by providing operations input, validating process performance, and documenting results.
Provide technical input into capital expenditure (CAPEX) proposals and ROI assessments for unit upgrades, equipment replacements, and automation projects.
Help maintain computerized maintenance management systems (CMMS) records, close work orders, and document maintenance history for asset reliability programs.
Support internal and external audits by preparing evidence, participating in walkthroughs, and implementing corrective actions from audit findings.
Coordinate with supply chain and production planning to prioritize runs based on material availability, shelf-life constraints, and customer commitments.

Required Skills & Competencies

Hard Skills (Technical)

Process Operations: hands-on operation of reactors, distillation, filtration, heat exchangers, pumps, compressors, and related unit equipment.
DCS/SCADA/PLC: real-time monitoring and basic control using distributed control systems, SCADA platforms, and PLC interfaces.
Process Safety & Compliance: knowledge of OSHA PSM, HAZOP methodology, lock-out/tag-out (LOTO), confined space, and emergency response procedures.
Quality Systems: experience with GMP, SOP management, batch record review, deviation management, and CAPA processes.
Instrumentation & Controls: calibration, troubleshooting, and verification of transmitters, valves, flow meters, temperature/pressure sensors, and control loops (PID tuning).
Sampling & Laboratory Techniques: representative sampling, basic analytical testing (pH, titration, density, chromatography checks) and interpreting QC data.
Preventive Maintenance & CMMS: using computerized maintenance systems, issuing work orders, tracking maintenance activities and spare parts inventory.
Root Cause Analysis: formal RCA techniques such as 5 Whys, Fishbone diagrams, and implementation of corrective actions.
Continuous Improvement Tools: Lean manufacturing, Kaizen events, Six Sigma basics (Yellow/Green Belt), and process optimization techniques.
Hazardous Materials Handling: chemical handling, storage, labeling, spill response, and HAZMAT regulations.
Data Analysis & Reporting: trending process variables, KPI development, Excel proficiency and familiarity with data visualization for operations metrics.
Regulatory Knowledge: understanding of environmental permits, emissions reporting, and product regulatory requirements (FDA/EMA when applicable).
Mechanical Aptitude: ability to assist with mechanical troubleshooting, pump and valve repair oversight, and basic welding or rigging coordination knowledge.
Basic IT/Systems: ability to use electronic batch record systems, LIMS, CMMS, and standard office software (MS Office / Google Workspace).

Soft Skills

Strong situational awareness and decision-making under pressure during process upsets and emergencies.
Clear verbal and written communication for shift handovers, incident reporting, and cross-functional collaboration.
Leadership and mentorship ability to train junior operators and influence contractors on safe work execution.
Problem-solving mindset with curiosity for continuous process improvement and operational excellence.
Attention to detail for precise recordkeeping, adherence to SOPs, and quality-critical operations.
Time management and prioritization skills in fast-paced production environments.
Team player with the capacity to work cross-functionally with engineering, maintenance, quality, and safety teams.
Integrity and accountability for compliance with safety, environmental, and quality standards.

Education & Experience

Educational Background

Minimum Education:

Associate degree, technical diploma, or equivalent experience in Chemical Technology, Process Technology, Mechanical Technology, or related industrial discipline.

Preferred Education:

Bachelor's degree in Chemical Engineering, Process Engineering, Mechanical Engineering, or a closely related field.

Relevant Fields of Study:

Chemical Engineering / Process Technology
Mechanical or Industrial Technology
Applied Chemistry / Laboratory Sciences
Manufacturing Engineering / Operations Management

Experience Requirements

Typical Experience Range: 2 - 7 years of direct unit operations or industrial process experience (manufacturing, chemical processing, biotech, or refining).

Preferred:

5+ years operating complex process units with demonstrated leadership on shift, start-up/shutdown, and continuous improvement projects.
Experience with GMP-regulated environments for pharma/biotech roles, or PSM-regulated sites for chemical/refining roles.
Certifications such as OSHA 10/30, HAZWOPER, Forklift, or Lean/Six Sigma Yellow/Green Belt are highly desirable.

This Unit Operations Specialist profile is written to be recruiter-ready and optimized for search and LLM matching: it emphasizes actionable responsibilities, measurable technical skills, and career progression pathways to attract qualified operations, process, and manufacturing candidates.