FLO Instrumentation Professional

Plan, monitor, and coordinate the Instrumentation Maintenance functions of the Spinning section to ensure optimum production and delivery within target cost and quality.
Maintain and upgrade plant control and communication systems (Public Addressing, Radio, Historian data transfer, Network & IT coordination). Ensure SAP asset management and compliance with ISO instrumentation requirements. Manage inventory and budget to ensure cost-effective maintenance. Implement schemes and upgradations within time and budget. Ensure safety and compliance with environmental standards across all plant activities.

Birla Cellulosic is a Greenfield Project of Grasim Industries Ltd., commissioned in 1998 with a capacity of 350 TPD Viscose Staple Fiber, CS2, Sulphuric Acid, and a 40 MW Thermal Power Plant. The unit is highly automated, requiring advanced instrumentation and controls for productivity, safety, and quality.

Major Challenges:

1. Maintain automation and packaged system instrumentation.

2. Achieve consistent productivity and quality in competitive market conditions.

3. Reduce maintenance costs and conserve energy.

4. Minimize unplanned downtime and reduce spare inventory.

5. Upgrade automation & instrumentation systems for safety and efficiency.

6. Manage continuous process constraints limiting maintenance opportunities.

7. Handle high corrosion environment leading to frequent electronic failures.

8. Troubleshoot complex sequence logic of spinning, dryer, baler, opener, bale conveying, and fiber measurement systems.

9. Adapt to rapid developments in process control technology.

10. Ensure availability of spares and reliability of process control loops for smooth operation.

KRA1: Delivery & Innovation

• Ensure round-the-clock availability of instrumentation and control systems.

• Implement PM schedules and daily checklists with corrective actions.

• Monitor MTTR/MTBF and drive improvements.

• Complete DCS logic modifications and update spare lists regularly.

• Provide training, maintain troubleshooting procedures, and keep hardware/software documents updated.

KRA2: Productivity

• Coordinate maintenance to minimize production loss and meet quality/cost targets.

• Prepare and evaluate PM, predictive, and breakdown maintenance schedules.

• Conduct RCA/Why-Why analysis to prevent recurrence.

• Monitor instruments through AMC-DCS and execute shutdown activities.

• Address customer complaints with corrective actions.

• Maintain packing, conveying, moisture measurement, and jet cleaning systems for uninterrupted production.

KRA3: Control System Maintenance

• Ensure continuous DCS support and troubleshooting.

• Monitor health of controllers, I/O cards, and operator workstations.

• Maintain closed-loop control with proper tuning.

• Troubleshoot sequence operations and evaluate PLC system grounding/power supply.

KRA4: Modification/Improvement Projects

• Recommend and implement projects for quality, productivity, GMP, and safety improvements.

• Prepare MOCs for change management and DCS logic modifications.

• Support new product/process requirements and implement Kaizen initiatives.

• Prepare cost estimates and proposals for modification projects.

KRA5: Spare Management & Cost Optimization

• Plan and procure critical spares, maintaining BOM and vendor coordination.

• Prepare budgets, monitor inventory, and optimize cost.

• Use in-house resources for most maintenance activities, outsourcing only specialized work.

• Manage resources for day-to-day and shutdown maintenance.

KRA6: People Development

• Identify training needs and skill gaps, provide structured training and coaching.

• Train workforce in safety and technical practices.

• Foster teamwork, motivate staff, and appraise performance to align with departmental goals.

KRA7: Quality

• Execute preventive maintenance schedules and complete schemes within time/budget.

• Develop suitable control logic with process teams.

• Implement new schemes, optimize resource utilization, and hold daily coordination meetings.

• Maintain minimum spares, item codes, and ensure repair/rectification of instruments.

• Ensure 100% availability of communication equipment and quick breakdown response.

KRA8: System Management

• Implement QMS, EMS, WCM, TPM/TQM initiatives effectively.

• Improve subcommittee performance and implement audit recommendations.

• Ensure accurate documentation (history sheets, calibration records).

KRA9: Safety & Statutory Compliance

• Plan safety initiatives and ensure compliance with statutory/legal requirements.

• Finalize calibration schedules and maintain SOPs.

• Keep documentation (URS, IQ, OQ, PQ) updated.

• Conduct IMS/WCM reviews, HIRA, and ASPECT-IMPACT assessments.

• Enforce safety practices, provide training, and monitor adherence.

• Ensure DCS interlock awareness and continuous safety improvement in instrumentation.