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 Show more Show less
