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Job Purpose: Write the purpose for which the job exists (in 2-3 lines) ( Max 1325 Characters) To take responsibility for mechanical maintenance of , MI Furnace and compressor house at Smelter 3, Birla Copper complex at Dahej to increase productivity and plant availability. To ensure operation of utility network in Smelter 3 in adherence of all protocols To ensure all statutory compliances, adherence to health, safety, environment norms and quality certification parameters with respect to mechanical maintenance and the processes they support. To continuously upgrade skills of the team and embed a culture of quality, safety and sustainability. Leading daily work management and culture of continuous improvement by implementing standards of excellence in AET9 & DMT1 Dimensions: Mention quantitative or qualitative parameters that are relevant for the job and provide a better understanding of the scope and scale of the job. Business Workforce Number (Max 254 Characters) MG 368, LMS 69. OG 1042, Contract workmen - 2881 Unit Workforce Number (Max 254 Characters) Staff (Management & LMS)- 437 Workmen- 1042, Contract Workmen- 2881 Function Workforce Number (Max 254 Characters) Staff (Management & LMS)- 437 Workmen- 1042, Contract Workmen- 2881 (Unit and business workforce no are same – To be corrected) Department Workforce Number (Max 254 Characters) Staff:52(Management), (LMS +OG) Company Workmen: 164 Contract Workmen: 306 Total Strength: 522 Nos Other Quantitative and Important Parameters for the job: Budgets/ Volumes/No. of Products/Geography/ Markets/ Customers or any other parameter Copper Anode Production Primary - 210000 T/yr. Gross Anode Production- 254122 MT COP Rs/MT- 32466 Treating approximately >750KT Copper concentrate /yr. To Produce anode production of 210KT /Annum 12 Rotating compressors, 4 Air Dryers, Furnace air cooling system, Cooling elements and its Water Circuit MI Furnace: 03 Furnaces (Smelting, Cleaning and Converting),S and C feeding pneumatic raw material system O& M Maintain 99% Uptime of Scrap charging system and utilities Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business/Unit/Function/Department/Section ( (Max 3975 Characters) Job Context Bi r l a Copp er i s a copper smelting and refining compl e x at Dah e j producing worl d cl ass C opper Ca t hodes, Continuous Ca s t C opper rods and P r ecio us Me t als besides other by-products like Sulphuric A c id, Pho sphori c Acid . T his position is responsible for mechanical & operation maintenance of , MI Furnace & compressor house at Smelter 3, Birla Copper complex at Dahej to support the smelting refining and production of finished copper and byproducts. The equipment includes 12 Rotating compressors, 4 Air Dryers, Furnace air cooling system, Steam network, MI Furnace: 03 Furnaces Smelting, Cleaning and Converting, pneumatic raw material feeding system, Cooling elements, Scrap charging system, feeding system for s and C at Smelter 3 has Mitsubishi technology which no longer provides technical support. Smelter is a continuous process with very little window for maintenance. Proactive planning and strategizing therefore required for preventive maintenance and upgradation, in coordination with service providers, where applicable, in order to maximize uptime. A key aspect of this role is to take responsibility for ensuring operation of Utility Pipeline of the Smelter 3 complex. The nature of technology, design and plant layout of Smelter 3 needs to have biannual shutdowns which also involve modifications. The regular maintenance has to be done while the plant is operational as this is a continuous process. Therefore, the planning process is complex. Planning preventive maintenance in coordination with the operation & Maintenance teams is critical. This role needs to ensure compliances with respect to statutory, health, safety, environment norms and quality certification parameters are not compromised for lack of maintenance of mechanically operated equipment in the above areas under jurisdiction. This role is required to ensure skill building of team members for higher productivity and efficiency of operations. Job Challenges Mitsubishi technology was Mitsubishi technology, being a complex continuous process, demands a high degree of operational discipline and control. The detailed engineering done by multiple vendors on basic engineering by Mitsubishi has a number of design flaws and layout complexities that make the process of engineering support difficult Environment within the plant is very hot and has exposure to dust and acidic fumes, making maintenance of sophisticated equipment a challenge. The operation deals with a lot of chemicals that are highly corrosive and this makes the mechanical equipment more prone to wear and tear. There is need to embed the culture of safety and sustainability Additional Responsibilities Safety and compliance: Adhere to workplace safety regulations and ensure its compliance with environmental and statutory standards, Follow LOTOTO procedures ,participate in Hazard identifications and risk assessments to ensure workplace safety Energy management (BOE) Accounts for energy conservation & optimization across plant operations Contributes to the continuous improvement initiatives including digital transformational and sustainable projects Provided mentorship & Training to teams ensuring knowledge transfer and skill development Work at height task member/convener & Mentor for BBSO sub committee task force Taking responsibility to work in different section and delivering results Compressor house equipment maintenance and its operation accountability Furnace all material and quality inspection and assurance and acceptance To Drive all initiatives across plant for improvement cultural change etc Ensure Equipment reliability, efficiency and safety of all mechanical systems with the copper smelter through preventive maintenance practices Trouble shoot and repair mechanical failures to minimize downtime in addition trouble shooting and conduct failure analysis Root cause failure analysis (RCFA) to identify chronic issues Maintain critical spare parts inventory and ensure timely availability and ensure maintenance activities align with ISO ,OSHO and other industry standards Key Result Areas/Accountabilities: Key Result Areas/Accountabilities Supporting Actions Planning Planning Capital Expenditure (CAPEX) for new or additional installations and system upgradations Preparing the annual Planning, budget, R&M budget operation and Maintenance to control costs without sacrificing sustainability issues Assessing performance of existing mechanical installations and preparing the annual preventive maintenance plan including shutdown in coordination with operating departments. Operational Excellence Ensuring productivity along with EHS norms. Tracking implementation of planned preventive schedule Analyzing data related to breakdowns and machine health, as per specified parameters, with inputs from O & M team Finalizing corrective action plan including shutdowns and predictive maintenance plan in case of any deviation Ensuring creation, modification and implementation of SMP’s, SOPs and SWI. Budgetary Controls Monitoring consumption of spares vis a vis R&M budgets on a quarterly basis Tracking of inventory and cost of procurement to operate with optimum level of stock and eliminate wastage Developing strategy and action plan for substitution of critical and costly spares with inputs from the team and adaptation of costly technology and equipment Compliances Verifying and approving Job Safety Analysis (containing specification of appropriate PPEs, classification of degree of hazard, nature of work permit required etc.) for daily maintenance jobs Conducting daily inspection round and interacting with relevant employees to embed safety culture through use of PPEs and safe work processes and minimize safety incidents and accidents. Ensuring all mechanical equipment and work processes, in area of jurisdiction, are always compliant with provisions of statutory requirement. Ensuring regular action and appropriate corresponding documentation to comply with guidelines of as per Integrated Management System. Facilitating bi-annual inspection and renewal of Compressor and its Receiver tank licenses for the smelter 3 Facilitating calibration of equipment on time Customer centricity Minimizing internal customer response time Ensuring timely completion of all jobs as per internal customer request Submitting MIS of performance of all machinery under jurisdiction on a periodic basis Facilitating vendor bill certification Facilitating the internal customer such as a Anode caster,SAP-3 and Refinery Sustainability and Systems Improvement Implementing good housekeeping practices and 5S. Reviewing sufficiency and technical viability of mechanical equipment in area under jurisdiction and their optimum utilization in light of present and future business needs Ensuring implementation of Corrective and Preventive Action Planning (CAPA) and other recommendation of audits. Ensuring implementation and horizontal deployment of corrective action to maximize machine contribution, plant availability and uptime. Steering and participating in Kaizens, Quality Circles, Task forces and other improvement initiatives Partnering creation and maintenance of green belt People Development and Engagement Monitoring manpower performance and identifying development action need. Monitoring training of team members to enhance technical competencies, improve behavioral effectiveness and embed a culture of safety Improving employee engagement Implementing 5S work culture Job Purpose of Direct Reports: Describe the job purpose of the direct report/s to the job (in 2-3 lines for each report) Position Title Job Purpose Position No. FLE Mech MI Furnace Takes care of day to day mechanical & Operation maintenance at MI Furnace in SM 3 FLE Mech Compressor Takes care of day-to-day maintenance at Compressor in SM3 Show more Show less
