Job Purpose
To Assist SH-MID to Conduct NDT test for all critical component in available identified list, identification of new components co-ordinate and execute coupling alignment activity of critical drives by laser machine. Prepare SAP data report related to PM orders and other notification. Assist and guide for implementing SAP as a power user team member. Ensure thermography schedule compliance.
Job Context & Major Challenges
UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. It is also one of the leading cement producers globally. UltraTech as a brand embodies 'strength', 'reliability' and 'innovation'. Together, these attributes inspire engineers to stretch the limits of their imagination to create homes, buildings and structures that define the new India.The company has consolidated capacity of 116.75 Million Tonnes Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 26 grinding units and 7 bulk terminals. Its operations span across India, UAE, Bahrain and Sri Lanka. UltraTech Cement is also India's largest exporter of cement reaching out to meet the demand in countries around the Indian Ocean and the Middle East.With a significant presence in the grey and white cement, concrete and building products segments as well as providing 360 degree building solutions, UltraTech is the one-stop shop for every primary construction need. Its meteoric rise as India's largest cement brand reflects on the organisation's focus on cutting edge technology, research and technical services.To maintain the leadership position of UltraTech in India and to achieve ambitious growth enabling to be prominent global player, warrants meeting vital need for technical expertise of high order.For a continuous process industry equipment maintenance planning is very important hence continuous review and awareness required for SAP PM module. By regular review, monitoring and refinement only we can achieve excellence, monitoring of critical component through NDT technic we can prevent unplanned stoppages of equipment and can ensure continuous operation of all production lines. By NDT techniques we can maintain our equipments health by timely correction and preventive action. We can have avoided unplanned and abnormal wear in of equipment’s and its rotating component by ensuring proper alignment of drive system.
Major Challenges
In view of very dynamic scenario with respect to:
- Smooth and trouble free operation of production line by Identification of hidden defect and estimate the fault severity and maintenance planning.
- Minimizing equipment failure and and spare parts cost through intensification of NDT techniques for all critical component in available identified list, identification of new components Co-ordinate and execute coupling alignment activity of critical drives by laser machine
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Timely co-ordination and conduct NDT test for all critical component in available identified list and to recommend necessary corrective actions to increase overall plant MTBF from baseline (last FY) by 10%. Decreased overall plant MTTR by 10% from baseline (last FY) Timely co-ordinate and conduct NDT test for all critical component in available identified list., analysis and recommendationData uploading in SAP.Creation of abnormal notifications in SAP.Report abnormalities for necessary actions. Technical Support Co-ordinate for checking correctness of technical tasks / problems.To give technical support to internal and external customers by providing required details as and when requiredKRA2 Co-ordinate and execute coupling alignment activity of critical drives by laser machine for smooth functioning of equipment 100% compliance. Co-ordinate and execute coupling alignment activity of critical drives by laser machine.Correct the mis alignment of equipment.KRA3 System development and Review: Weekly monitoring of Preventive maintenance order for plant, TPP and Mines.100% compliance of SAP PM Order and notifications To prepare weekly compliance report for PM07 orders, abnormality notification, why-why analysis and all recommendation of why-why analysis.To support SAP PM users for SAP PM module implementation and trouble shooting.KRA4 System Management(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) To implement improvement project to reduce repetitive problems/breakdown or losses.Timely submission of Kaizen, OPL, Good to fine, suggestion on systemDeveloping and sustaining Model area in respective sections100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programmes down the level teamTo know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.Implementation of critical spares & consumable SOP without any defilementIdentify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.KRA5 Focus on SHE (Safety, Health & Environment) along with Sustainability initiatives Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.Educating team about “I know my job”, “I know the hazards associated with my job and I applied control measures” & “I escalate to my senior” among manpower deployed in sections/department manpower including peer, WB & CL manpowerTimely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWPActive participation in safety training, safety sub committees, standard champions meeting and any safety eventEnsure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective actionAdhering of all safety precautions on the site and off the siteReplicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.KRA6 1) Safety AssuranceEnsure implementation of all safety provisions for workmen & self ¿ Ensure use of PPE¿ Take work permit before carrying out any job¿ Implement all safety provisions as per SOP¿s.
KRA7 2) Quality Systems
Implement ISO, EMS, WCM , SA8000 & OHSAS related activities to improve productivity & quality standards ¿ Identify and execute improvement study and kaizen.¿ Identify & get rectify.
- Abnormalities.
- Spillage/leakages.
- Unsafe conditions/practices.
5S activities.
- Points emerged in campaigns..
¿ Execute implementation plan for
- Strategic quality projects.
- Quality improvement objectives.
- Improvement of WCM criteria score.
- EMS targets.
- Internal customer rating improvement.
- ISO system improvement.
- Statutory compliance.
- Elimination of muda.
¿ Does why why analysis.
¿ Prepare/present weekly/monthly WCM presentation.¿ Develop one point lesson.¿ Update WCM activity boards.¿ Develop Model area.¿ Develop visual controls.
