Job Purpose
- Deliver P&B targets by focusing on Safety, Equipment upkeep and reliability through effective use of various maintenance practices and execute projects to increase overall equipment effectiveness (OEE) of the assigned Area.
- Handhold DMT members in daily asset care practices, propagate a culture of continuous improvement, and ensure EHS & other statutory compliance in the area through collaboration with other AET members.
Job Context & Major Challenges
Job Context
Birla Copper is a copper smelting and refining complex at Dahej producing world class Copper Cathodes, Continuous Cast Copper rods and Precious Metals besides other by-products. The complex has Smelters, Refineries and multiple process plants including Sulphuric Acid Plants, Precious Metal Recovery Plant, as well as Captive Power Plants, Oxygen Plants, WTP- ETP, captive Jetty, residential complex and a CJST medical Center. Birla Copper Dahej plant is spread over 342-acre land and out these 129 acres is covered by green belt. Birla Copper Dahej is India’s leading copper producer and exporter. It is having captive Jetty (DHIL a wholly owned subsidiary). 23 fully integrated & interdependent plants at one location and 5 industry segments & 15 technologies. It is highly Logistics intensive, 5 million TPA material handling (600 trucks per day & 100 ships per year). It is highly import and export-oriented plant Global Supply Chain - Sources and Export in more than 10 countries. It is having captive Power Plant capacity of 135 MW. (20 MW Solar + Hybrid) and Daily water requirement of 20,000 m3/day (10,000 m3/day Desalination water).Product Vertical comprises of Six departments: Two CC Rod plants, One RBD plant, PMR Plant, Jetty, Special Projects (Fertilizer Dismantling and Gypsum/Slag Yard Management) and Technical Services. The Vertical is responsible for manufacturing and support marketing of all products of Downstream business. The Vertical also is responsible for Product Planning, Quality Assurance Laboratory and Customer Centricity for Downstream business. The current products include Cathodes, Rods of various sizes, Alloyed rods, Wires of various Sizes, Gold, Silver, Selenium, PGM and byproducts include Gypsum and Dore Slag. Every Department is unique, quality challenged, Customer driven and highly automated single line operations.The Precious metal Recovery Plant is the only primary gold and silver producing plant in India. Pure metal is recovered from the de-comprised anode slime generated from the refinery. It is a complex process involving operations through furnaces, reactors, tanks, bag filters, scrubbers etc. Recovery of precious metals is again crucial for efficient operations.This role is responsible Sustainable maintenance of PMR by finding creative solutions to long standing issues and recognizing DMT team members for good work. The most critical element of the role is maintaining equipment availability to get desired production target.
Job Challenges
- Understanding of PMRP operations in details to know chemical reaction, chemical composition, metal composition. Maintaining of equipment availability to produce gold, silver, selenium and PGM.
- Due to PMRP Space constraint require stringent focus on safety of all jobs, and complete the jobs on time to meet targets of production.
- Focus on Daily management of DMT and working with cross functional team to improve the plant overall availability by trouble shooting of problems.
- TROF & SRF area maintenance in limited space. Any deviation in maintenance of SRF and TROF will leads to loss of gold, silver and selenium production.
- Maintaining of Selenium recovery furnace vacuum and circulation system. Failure of both system leads to production loss as well as highly impacts on human health, environment and safety.
- Keeping healthiness of TROF’s ID fans and bag filters. As both equipment’s are handling highly corrosive, sticky and hazardous gases leads direct impact on environments.
- Maintenance of gold and silver refinery system. Handle Highly corrosive liquids and generate fumes. Closed building, security system, man & material single entry require more focus on all jobs.
- Attending any kind of gas and liquid leakages in Trof and SRF section. Both sections have highly corrosive, hazardous and flammable gases and liquids. Each area requires to stringent attention on each activity.
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Safety & Workplace Management
- Drive strategic / large scale improvement initiatives under the guidance of PBU Head and ensure all statutory requirements in the Area are met with focus on air and water pollution control, for hazardous wastes and effluents.
- Implement procedures & plans, for compliance with statutory, regulatory & environmental norms and HIL standards for Occupational Health, safety & environment.
- Identify health hazards that arise out of occupational, design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
- Drive Kaizen and other improvement initiatives for greater sustainability of operations.
- Maintain workplace in order with respect to all Sub-areas (Level of 5-S).
- Comply with safety standards & procedures (work permit system, storage and handling of hazardous material, etc.) for accident prevention in the Area.
- Ensure complete implementation of LOTOTO (Look-Out, Tag-Out & Try-Out) guidelines for personnel safety.
KRA2 Daily Work Management
- Drive flawless daily work by undertaking following: Implementation of DMTs excellence standards across the Area Achievement of monthly, quarterly and annual P&B targets of the assigned Area in terms of quantity & quality Evaluation of Daily Performance Indicators (DPIs) of the team.
- Set & communicate clearly defined KPIV & KPOV (Key Performance Input / Output Variables) to DMTs with all the related costs.
- Undertake 'Abnormality Identification' in DMTs through Root Cause Analysis and address unfavorable deviations through countermeasures (Kaizen, SPL, Visual Controls, Mistake proofing, Change in SWI, etc.)
- Define work priorities, execute plans on day-to-day basis pertaining to SQCDPM, and review Root Cause Analysis of any unfavorable deviations in last 24 hours.
- Undertake daily & periodic 'Job Planning' through ERP system (Maximo / Ekayan) for efficient daily work flow.
- Undertake & monitor material, manpower & contractor job planning and resource deployment & arrangement as per need, to maximize profitability.
- Define Model areas / machines devoid of unwanted items and make abnormality Identification (8 types) & redressal as a continuous process in all DMTs (5S & Kaizen).
- Manage daily Operations, Production & Maintenance and take related decisions within the allocated budget.
KRA3 Continuous Improvement
- Ensure continuous improvements using problem solving tools (RCA, OPL, Kaizen, ATOMS, Minitab, etc.)
- Drive FI, PI, Just Do It, Value Creation, and other improvement initiatives to improve productivity & cost efficiency of the Area.
- Create value through waste elimination, optimum resource utilization, productivity enhancement, etc.
Identify & eliminate inefficiencies and NVAs in the system for streamlining.
KRA4 Asset Care & Equipment Reliability
- Ensure equipment availability & health in the area by following measures: plan & implement preventive maintenance, track reliability testing & predictive maintenance, facilitate shutdown & overhaul, and ensure timely breakdown maintenance with functional support from CoE Asset Care, if required.
- Ensure implementation of best maintenance practices across the PBU and monitor its effectiveness in coordination with CoE-Asset care, to attain higher uptime of Plant and equipment.
- Achieve zero production loss due to equipment related breakdowns by following measures:
Ensure availability of critical spares
Use ERP System (Maximo / Ekayan) and ensure complete adherence with maintenance schedule.Facilitate / Conduct Equipment Criticality Analysis to identify gaps & anticipate issues proactively and recommend solutions.
- Undertake Root Cause Analyses of breakdowns, to minimize process disturbance and production delays.
- Control overall cost of maintenance by following measures: track spare consumption by conducting regular reviews, control spare inventory at optimum levels, explore possibility of using import substitutes and undertake other innovative cost optimization projects.
- Ensure effective utilization & control of manpower, overtime, and store expenses through recycling spares and waste reduction.
KRA5 Process Care & Quality
- Drive the culture of structured problem solving by ensuring implementation of FI, Just Do It, and any other project which is derived from chronic issues.
KRA6 Customer Centricity
- Meet and exceed internal & external customer expectations, adhere with service level agreements (SLAs), and implement action plans based on ICSI, customer feedback & surveys.
KRA7 Capability Building & People Engagement
- Develop Skillset of DMT members and maintain optimum Skill inventory.
