KILN,COAL-MECHANICAL

Purpose/Objective

The Section Head - Kiln and Coal Mills (Mechanical) is responsible for managing all mechanical maintenance activities related to the Kilnand coal mills, ensuring optimal plant availability and reliability. This role focuses on preventive and predictive maintenance, safety compliance, and continuous improvement. By leading shutdown management and spare parts optimization, the role ensures cost-effective operations and alignment with production goals while driving the adoption of best practices.

Key Responsibilities of Role

Kiln Maintenance Management: Plan, organize, and coordinate all maintenance activities related to the Kiln and Coal Mills, ensuring optimum plant availability and minimal downtime. Execute improvement and modification projects aimed at reducing operational costs and enhancing productivity, with a focus on critical kiln and mill components. Preventive & Predictive Maintenance: Implement and oversee preventive maintenance routines for Kiln and Coal Mills equipment, ensuring timely execution in coordination with the Maintenance and Production teams. Utilize predictive maintenance techniques, such as vibration analysis and thermography, to anticipate and address potential equipment failures. Equipment Reliability & Performance: Monitor and manage the reliability of Kiln equipment, ensuring adherence to the desired operating conditions and achieving high net availability. Lead efforts to maintain and improve the Mean Time Between Failures (MTBF) for the Kiln and Coal Mills. Safety & Environmental Compliance: Enforce strict adherence to safety protocols, including LOTOTO procedures during stoppages, to ensure a safe working environment. Ensure that maintenance activities comply with environmental regulations, minimizing emissions and ensuring pollution-free operations. Shutdown & Overhaul Management: Plan and manage major and minor shutdowns for the Kiln and Coal Mill, ensuring efficient execution and alignment with production schedules. Oversee critical maintenance tasks during shutdowns, such as tip casting, gear box alignment, and dip tube replacement, to ensure long-term equipment reliability. Spare Parts & Inventory Management: Manage the availability and optimization of spare parts for Kiln and Coal Mill maintenance, ensuring critical components are readily available while minimizing inventory costs. Collaborate with the Preventive Maintenance Planner to align inventory levels with planned maintenance activities and unforeseen repairs. Continuous Improvement & Best Practices: Drive the implementation of best practices in Kiln and Coal Mill maintenance, focusing on the continuous improvement of maintenance processes and the adoption of innovative technologies. Analyze maintenance data to identify trends and opportunities for process optimization, leading initiatives to improve equipment performance and reduce operational costs. Reporting & Documentation: Ensure accurate documentation of all maintenance activities, including daily inspections, preventive maintenance, and shutdown reports. Prepare and present reports on Kiln and Coal Mill maintenance performance, including equipment reliability, safety incidents, and compliance with maintenance schedules. Internal Control & Transparency: Implement and monitor internal control systems to ensure accuracy, reliability, and transparency in daily operations Regularly assess and identify potential risks within the organization, recommending and implementing control measures to enhance transparency Key Stakeholders - Internal: Mechanical Maintenance Head Maintenance Engineer - Kiln Production Head Preventive Maintenance Mechanical Planner CBM Incharge Key Stakeholders - External: Vendors and Suppliers Regulatory Authorities

Technical Competencies

Energy Recovery Optimization-Cements,Equipment Maintenance-Cements,Lean Six Sigma-Cements,Material Science Expertise-Cements,Mechanical Design Optimization-Cements,Mechanical Engineering Innovation-Cements,Process Control Systems-Cements,Quality Assurance-Cements,Rotary Kiln Design & Operation-Cements

Qualifications and Experience

Education Qualification: BE in Mechanical Engineering. Work Experience: 10+ years of experience in mechanical maintenance, with significant experience in kiln operations within the cement industry. Industry Knowledge: Strong understanding of kiln maintenance and reliability practices, including predictive maintenance techniques and shutdown management.