Job Purpose
Plan Monitor and Coordinate the Instrumentation Maintenance Functions of CS2/Acid & WTP/ETP sections so as to ensure Optimum Production and delivery with target Cost and Quality.
Job Context & Major Challenges
Job Context
Birla Cellulosic is a Green Field Project of Grasim Industries Ltd. The project was conceptualised in the year 1994 and was fully commissioned in 1998. The unit has an installed capacity of 350 TPD of Viscose Staple Fibre and is the most modern Viscose Staple Fibre producing unit of Grasim As pulp & Fibre business, with its four manufacturing streams of Viscose Staple Fibre of 350 TPD, 59.1TPD Carbon di Sulphide (CS2), 400 TPD of Sulphuric Acid, 40 MW Thermal Power Plant and other auxiliary plants like Water Treatment, Demineralisation & Effluent Treatment Plant etc. Grasim As pulp & fibre business has grown over a period of last 50 years and has matured in terms of cost, quality & productivity. Today Grasim As Viscose fibre is branded as `Birla Viscose and is considered as most environment friendly textile grade viscose fibre known for its feel & comfort. Birla Cellulosic As plant was put up to further strengthen the groups market leadership in the fibre business and expand its share in the world market by producing best quality product. With the vision of making the plant a world reference point in terms of quality the project was provided with most modern state of art machinery & instrumentation. The process of Viscose Staple Fibre is a continuous chemical process & the accurate process control is achieved by most modern distributed controls & programmable logic controls. High level of automation eliminates human error and ensures trouble free operation of the process. Thus instrumentation and controls play a key role in ensuring best product quality & productivity of operations. The major challenges for the position.Main Challenges with us are: To ensure safety of each team members during working at shop floors by sustenance of safe work practices, and motivating teammates to comply so.
- CS2 and Acid plants are a continuous line production processes; Hence any line instrument or control system breakdowns directly affect quality and quantity of production.
- Highly Corrosive environment leading to high level of corrosion of electronic cards, resulting in higher failure rate.
- To track and upgrade with micro level planning, execution of obsolete control systems, field instruments and panels.
- To maintain uptime of critical control systems like PLCs. Competitors are more aggressive for Product quality and quantity. Thus there is need of consistence productivities and quality to satisfy customers need.
- To plan, co-ordinate and execution of production enhancement and debottlenecking schemes with running maintenance is one of the challenges.
To control unplanned down time, reduction in inventory, control use of revenue budget.
- Focus on Maintenance cost reduction and Energy conservation. 9. Betterment of Instrumentation & Automation system to ensure safety.
- To ensure safety of standalone networks for virus attacks and malwares as systems are hooked up with external IT networks.
- To coordinate cross functional teams during troubleshooting of complex problems of equipment’s and resolving with minimum time.
- To execute shift operations of instrument technicians (07 no’s), planning, co-ordination with them for leave planning, emergency handling and ensure supports during critical jobs.
- Upkeep TOC data to GPCB network, coordination with the irrigation dept. for calibration of the meters and maintenance of Weighbridge.
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Upkeep
Monitor & coordinate maintenance activities of VSF plant so as to achieve optimum production loss & delivery within target cost & quality Parameters.
- Ensure the availability of instrument and PLC systems to meet the manufacturing targets and other customer requirements
- Preventive Maintenance Schedule preparation & Evaluation
- Predictive Maintenance Check list preparation & Evaluation
- Breakdown maintenance job Execution & guidance to subordinate
- RCA & Why-Why Analysis to avoid repeated problem
- Health Monitoring of Instrument through AMS-PLC
- Shutdown Activity execution & co-ordination with process team
- Review customer complaints and take relevant corrective action
- Focus on Reduction in Unplanned Instrument Downtime
KRA2 Control System Maintenance
To ensure continuous PLC support & trouble shooting
- Ensure the availability of control systems to meet the manufacturing targets and other customer requirements
- Health monitoring & corrective action to maintain uptime of Controllers , I/O cards, servers & operator work stations
- Ensure closed loop controlling by monitoring final control element function & tuning parameter setting
- Control system Preventive Maintenance Schedule preparation & Evaluation
- Ensure PLC system availability by maintain Grounding & power supply within limit
KRA3 Modification/Improvement Projects : To suggest the modification / improvement projects to improve quality & productivity
- Ensure product development and plant up gradation to ensure long term liability
- Introduce technological change for improved Quality, Safety with cost effectiveness.
- MOC preparation /evaluation for change management process
- PLC logic modification for quality & productivity improvement as per process requirement
- Provide the services & equipment needed for new products and formulation changes
- Identify/Evaluation of KAIZEN for implementation
- Working upon cost estimation of small modification & improvement project & its proposal making
KRA4 Spare Management & Cost Optimization
Planning & Monitoring spares management to ensure better cost optimization.
- Identifying and procuring the required equipment spares and accessories by proper planning and follow up inspecting and accepting the incoming materials with respect to indents raised.
- Maintaining BOM for Instrument apparatus
- Procuring required materials by floating enquiries, conducting techno-commercial comparison , dealing with vendors & so on
- Prepare yearly budgets and Work services to meet targeted requirements and controls.
- Review budget & Inventory Control by spare material criticality analysis
- Ensure Maintenance contract are awarded only for special Instrument, rest all activities carried out by utilizing in-house resources
- Ensure resource management for day to day & shutdown activity
KRA5 People Development
To enhance knowledge & skills of team/subordinates.
- Identifying training needs, Skill gap & recommendation for skill improvement
- Development of maintenance team by structural training & job coaching
- Train the workforce for safe practices & technical subject for maintain the control system to meet all the environment standard
- Inspires & stimulate subordinate to maximize their performance towards department goals
- Developing team work culture
KRA6 Safety & Statutory Compliance
To plan the various safety initiates to create safe working condition & also meet the statutory compliances.
- Critical Instrument Calibration frequency finalize, Schedule preparation & Evaluation
- Ensure that all Calibration activities are completed within the due date and all the SOPs are “current” and are in use by the concerned person
- Updating & Maintaining documentation related to projects like user requirement specification, installation, operational & performance qualification
- Ensure timely review of IMS, WCM, process safety documents to meet the respective standard requirements
- Review of Policies ,readiness for internal & external audit compliance
- Identify department HIRA , ASPECT-IMPACT & ensure implementation
- Six step Safety Observation process follow-up as per schedule
- Betterment of Instrument System to Ensure Safety
- Ensure safety practices implementation within team
KRA7 7) People Development Identifying innovative works and to motivate for more developmental activities.
 Proper guidance and support to technicians. Training imparted to increase multi skilling amongst work force.KRA8 8) System Management Ensure implementation of QMS/EMS, World Class Manufacturing (WCM) SC & other TPM / TQM initiatives
- Â Enhance the working of SC in the department improve the monthly score.
 Take corrective steps for effective implementation of WCM sub committee.
 Implement recommendations of audit & close non-compliances. Review of proper filling of history sheets and calibration sheets.
