Job
Description
Job Purpose
To monitor for all key functions of Copper 3 (Mitsubishi Continuous copper smelting, Cl Furnace, C Furnace Anode Furnace, Utility and ACID Plant ) like operations, maintenance (Mechanical, Electrical & Instrument) and quality to deliver Copper Anodes required for Copper Refinery ensuring flawless daily work management, continuous improvement, and value creation at business level as per planning and budgeting, Environment, health, and safety norms and driving for sustainability.
To collaborate with COE-Process Care, COE-Asset Care, Improvement cell and shared services and leverage their expertise to achieve aspirations and capability building of the team to achieve defined ROAD map fulfilling both short term and long-term objectives of PBU.
Dimensions:
Business/SBU/Unit Revenue
50000/35000/15000 cr.
Business Workforce Number
MG 368, LMS 69. OG 1042, Contract workmen - 2881
Unit Workforce Number
Staff (Management & LMS)- 437
Workmen- 1042, Contract Workmen- 2881
(Unit and business workforce no are same – To be corrected)
Function Workforce Number
Staff: 132 (Management), 95 (LMS)
Company Workmen:
433
Contract Workmen: 659
Total Strength
: 1319 Nos
Department Workforce Number
Staff: 47(Management), 27 (LMS)
Company Workmen:
138
Contract Workmen: 322
Total Strength
: 534 Nos.
Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter
Copper Anode Production- 254000 T
Acid Production- 750000T
P&B Cr. Copper 3
Stores Expenses- 8.29 Cr
Contract Expenses: 10.05 Crs,
Capex Budget:
Variable Crs
Job Context
Birla Copper unit at Dahej is a copper smelting operation having two operational copper
smelters to process blended copper concentrates of varying specifications to supply copper in
the form of anodes of 99.5% purity to the refineries attached to them. This position is
responsible for operation and maintenance of Copper Smelter 3 supplied by Mitsubhishi. This is
the most complex and continuous smelting copper smelter technology. Analysing and
understanding the copper concentrate blend composition and achieving optimum output with
required quality parameters is a key aspect of this role. The operation involves hazardous
processes and generation of corrosive and toxic intermediate products which need to be
monitored to be able to keep emissions such as SO2 within permissible limits. The role involves
strict compliance of statutory stipulations and compliance of quality, safety, health and
environment parameters as well as energy conservation. It requires continuous process
improvement and training.
Job Challenges
Heterogeneous nature of raw material causes blend to take 1-2 days to stabilise and changes
every 4-5 days. This continuously changing raw material profile and varying quality results in
Fluctuation of output of smelting furnace
Operational issues impacting plant availability
The process of accurate sampling, analysis and metal accounting becoming very complex
WIP needs to be minimised by maximizing liquidation so as not to block cash flows:
Liquid copper in ladles and launder tend to solidify if not monitored closely.
Explosive blasting is done in the boiler to disintegrate rock formation of copper and other impurities.
Plant is old and needs upliftment, making achieving plant uptime a challenge.
Process is hazardous with corrosive, toxic emissions, minimising emissions within PCB
Norms and meeting other environmental and safety norms difficult.
Obtaining employee with specialized skills and experience of non-ferrous metallurgical
Process and keeping people motivated in the ambience of the copper is a constant challenge
Key Result Areas/Accountabilities:
Key Result Areas/Accountabilities
Supporting Actions
Production
To deliver required Copper Anode production with quality as per refinery requirements and P&B.
Manage the operations, and maintenance (Mechanical, Electrical & Instrument) of the Precipitation circuit, Seed filtration circuit, calcination and by-product circuit along with utilities. Review to ensure no deviations in processes.
Setting goals and targets (KPIs) for AET/DMT and ensuring progress and deadlines are met for improvement initiatives.
Ensure complete alignment and synchronized rhythm of work between PBU/AET and COE.
Ensuring quality of as per Refinery demand.
Driving flawless daily work management system by implementing AET / DMT excellence standards across PBU and ensuring desired physical attributes, and metrological properties with adherence to quality parameters of Alumina and Providing guidance and support to AET/DMT/SME alliance.
Review to ensure structured processes/practices are institutionalized for sustainability and implementing Improvement projects to solve chronic issues and effective plant operations.
To institutionalize the process of reviewing Daily Performance Indicators (DPIs) of AETs and DMTs across PBU periodically and provide the necessary support to excel in their performance by developing systems for Abnormality Identification in AETs/DMTs and Plan for elimination
Ensure asset care practices are implemented for availability and reliability as per P&B in PBU.
Review the effectiveness of SOP and SMP and analyse and recommend for appropriateness of SOP/SMP of PBU.
Cost
To be cost efficient
Ensure PBU budgeting (Capex & Operating) considering the annual business plan.
Review and monitor direct and indirect costs and ensure spending within P&B.
Ensuring achievement of cost saving without compromising quality and delivery by driving cost-saving initiatives, other major initiatives for reducing production costs and de-bottlenecking.
Identify value creation projects/ facilitate ideas from team members around “Value destruction” and “Missed Value Creation” areas and ensure their implementation.
Ensure Implementation of FIT/ Just DO It Projects/ chronic issue resolution as per the structured process.
Cash
To improve working capital
To ensure store inventory is under control and within the P&B limits.
Ensure execution and utilization of cash flows for Capex projects as per plan.
Customer Centricity
Fulfil internal & external customer expectations for satisfaction and reliability, cost, and delivery
Ensuring meeting Internal of customer expectations by honouring service level agreements (SLA)
Ensure implementation of the action plan as per feedback from internal customer satisfaction surveys.
Collaborate with the customer and COE-Process Care to ensure the supply of quality products within the limitations of varied raw material quality.
Ensure Customer Relationship Management through PST and customer-supplier meetings
Drive customer centricity as a culture in the team
Managing and monitoring the contracts and relations with customers, vendors, partners, and other stakeholders as per regulation
Sustainability & Compliance
Develop and implement the roadmap for sustainable practices
Ensuring compliance with all statutory and environmental norms in PBU.
To develop a roadmap for achieving plant/ business aspirations and ensure its implementation for short-term and long-term sustenance.
To develop Heat Map, prioritize the areas for improvement and ensure its implementation as per plan.
Ensuring compliance with statutory norms and HIL standards for Occupational Health, safety, and environment etc.
Controlling and maintaining the discharge of pollutants as per statutory norms & adhere to ZLD plans for all units of Copper 3 PBU.
Driving strategic/large-scale improvement initiatives to ensure all statutory requirements are met.
Ensuring that the workplace is in order with respect to all Sub-areas (Level of 5-S).
Ensuring compliance with the Integrated Management System and Energy Management System
Safety, Health, and Environment
To ensure zero harm by building a culture for safety and valuing Human Lives
Embedding a safety culture by spreading awareness to build a safety culture, implementing safety standards, developing safety mechanisms, and ensuring safety-related training is imparted to achieve zero harm by working in close coordination with all stakeholders.
Ensuring e mergency handling readiness of all cross-afunctional teams across the PBU.
To create a safe work environment by designing/re-engineering/Continuous Improvements.
People development and engagement
Building Capabilities of Employees and enforcing a culture for people development and sustainability
Ensuring all people development processes driven by the business are implemented in the PBU
Monitoring intake and deployment of the appropriately trained contractual workforce and ensuring their continuous training and well-being as per company guidelines
Monitoring and improving the performance of team members of AETs/DMTs by capability building.
Identifying skill-based training needs and facilitating skill enhancement through HTU.
Driving interdepartmental mobility through multiskilling.
Reviewing, monitoring, and ensuring implementation of all action plans as an outcome OHS/Dipstick survey to develop leadership pipelines and improve team engagement scores.
To motivate and ensure engagement and involvement of all team members with enhanced morale.
Role Specific Competencies
Technical competencies
Degree in Engineering preferably Metallurgy/Mechanical with adequate relevant & troubleshooting experience
Behavioural competencies
ABG Leadership Competencies
Job Purpose of Direct Reports:
Position Title
Job Purpose
Position No.
AET Leader- Mi Furnace and utility
Plan, execute and ensure implementation of cross functional working, operation, maintenance (Mechanical, Electrical & Instrument) & process control, in Mi Furnace and utility area to deliver production, cost, quality, delivery with compliances to safety and environmental standards as per planning and budgeting.
To execute program on capability building of the teams and driving improvement initiatives for sustainability of the plant and processes.
AET Leader- Off gas Area
Plan, execute and ensure implementation of cross functional working, operation, maintenance (Mechanical, Electrical & Instrument) in Off gas area to deliver production, cost, quality, delivery with compliant to safety and environmental standards as per planning and budgeting.
To execute program on capability building of the teams and driving improvement initiatives for sustainability of the plant and processes.
AET Leader- Bedding plant and Dryer
Plan, execute and ensure implementation of cross functional working, operation, maintenance (Mechanical, Electrical & Instrument) in converter area to deliver production, cost, quality, delivery with compliant to safety and environmental standards as per planning and budgeting.
To execute program on capability building of the teams and driving improvement initiatives for sustainability of the plant and processes.
AET Leader- Anode furnace and casting,
Plan, execute and ensure implementation of cross functional working, operation, maintenance (Mechanical, Electrical & Instrument) in Anode furnace and casting area to deliver production, cost, quality, delivery with compliant to safety and environmental standards as per planning and budgeting.
To execute program on capability building of the teams and driving improvement initiatives for sustainability of the plant and processes.
AET Leader- Sulphuric acid plant
Plan, execute and ensure implementation of cross functional working, operation, maintenance (Mechanical, Electrical & Instrument) in SAP 1 area to deliver production, cost, quality, delivery with compliant to safety and environmental standards as per planning and budgeting.
To execute program on capability building of the teams and driving improvement initiatives for sustainability of the plant and processes.
Relationships:
Relationship Type
Frequency
Nature
Internal
Verticle Head
Daily
To apprise about status of daily plant process
To discuss about new projects / ideas of improvement
PBU Head – Refinery
Daily
For coordination between Refinery and Smelter 1 area and understand the planning and plan the area operations accordingly.
COE Head-Asset Care
Daily
For implementation of Capex projects & continuous improvement in terms of workflows, machine efficiencies and enhancement of product quality and any new development
COE Head-Process Care
Daily
For problem solving with respect to quality parameters and process improvement
Head Improvement Cell
Weekly
For review of various FIT , CAPEX, MI, LVPs
Support on smooth working of DMTs & AETs
Head Commercial, HR & Projects
Monthly
For Purchase requisition & Orders of critical & urgent items and other support services and driving & execution of capex / improvement projects and Sustainability related initiatives Human related requirements
External
Legal and Sustainability Cell including CPCB and MCOE as well as Factories Directorates
As and when required
For compliance with respect to pollution control, environment norms, tools, and tackles etc.
Safety Department
As and when required
Organizational Relationships:
Position that it reports into
Position and its peers
(NoP= 6)
Position/s that report into
(NoP= 5 )
Copper Vertical Head
PBU Head- Copper 1
PBU Head- Copper 3
PBU Head- Refinery
AET-RMH
COE Head-Asset Care
Head-Improvement Cell
AET Leader- Mi Furnace
AET Leader- Offgas, Boiler and ESP
AET Leader – Bedding and Dryer
AET Leader Anode furnace , casting
AET Leader -Acid Plant 3
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