Job Purpose
Plan Organise & Co-Ordinate the implementation of Field Operation &maintenance activities in Kiln & Cooler for optimum plant availability within optimum cost to meet production target, Execution of improvement / modification jobs for cost reduction and productivity improvement along with manpower planning and spare parts management, system implementation for best practices by ensuring pollution free and safe working environment.
Job Context & Major Challenges
Job Context: UltraTech Cement Limited is the cement flagship company of the Aditya Birla Group. A USD 7.9 billion building solutions powerhouse, UltraTech is the largest manufacturer of grey cement, ready mix concrete (RMC) and white cement in India. It is the third largest cement producer in the world, excluding China. UltraTech is the only cement company globally (outside of China) to have 100+ MTPA of cement manufacturing capacity in a single country. The Company's business operations span UAE, Bahrain, Sri Lanka and India.UltraTech has a consolidated capacity of 138.39 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals. UltraTech has a dealer network of over 30,000 and retailer network of over 84,000 across the country, with a market reach of more than 80% Indian cities and towns. In the white cement segment, UltraTech goes to market under the brand name of Birla White. It has one White Cement unit and three Wall Care putty unit, with a current capacity of 1.98 MTPA. With 230+ Ready Mix Concrete(RMC) plants in 100+ cities, UltraTech is the largest manufacturer of concrete in India. It also has a slew of speciality concretes that meet specific needs of discerning customers. Our Building Products business is an innovation hub that offers an array of scientifically engineered products to cater to new-age constructions.Narmada Cement - Jafarabad Works was established in 1982 as Narmada Cement Company Limited and merged with UltraTech in 2006. The installed capacity of 1 MMTPA clinker has been gradually increased to 1.50 MTPA (4,300 – 4,500 TPD). Cement capacity is 0.50 MTPA (1,150 TPD).It is India’s first split location dry process cement plant with Fuller technology having four-stage suspension pre-heater, in-line flash calciner, reverse air bag house dust collector, vertical roller mills besides to be the first to unload imported South African coal at plant jetty. It transports 100% clinker to grinding units is in bulk by sea route. The special feature of this plant is ‘Just in Time’ design for raw mill circuit. As against conventional norms of 20,000 MT silo for raw meal storage it has 2,000 MT silo.The grinding units associated with Jafrabad Cement Works are Magdalla Cement Works and Ratnagiri Cement Works. All three coast-based split location clinker manufacturing units have jetties. Narmada Cement was the prime supplier of fly ash-based Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada, which is the World’s second largest concrete gravity dam (by volume).Narmada Cement Mine is the captive mine for Jafarabad plant having a production capacity of 2.30 MTPA. It is situated near coastal village of Babarkot, 7 km from Jafarabad port. Out of the total 565.94 hector lease area.
Job Challenges
- To ensure 100% Equipment availability for 365 days continuously.
- Maintain zero accident, to ensure 100% Implimentataion of systems like QMS,EMS,OHSAS,WCM and SAP, Controlling of maintenance expenditure well within norms.
- Coordinate the challenging of execution of manintenance related activities.
- Ensure pollution free environment to improve manpower efficiency and productivity.
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
Kra1 Plant Availability
Plan, Organise and monitor implimentatin activities for optimum plant availability in MechanicalDescipine as per target to meet production from cement mill as per requirement and satisfactionof internal customers.Coordinate the challenging of implementation / execution of maintenance activities Execution of preventive & corrective maintenance activities.Ensure periodic checking.Manpower planning one day in advance for daiy jobs.Proper Job planning for shutdown jobs.Spare parts planning for manjor shutdown jobs as well as fulfilling day to day basic requirements.Analysis of major / minor breakdowns and plan corrective actions accordingly.Interaction with OEM and suppliers for elimination of critical equipment problems.Execution of all the major jobs during shutdowns.Planning of contractor jobs to be carried out and raise service work order accordingly.Attending coordination meeting regularly for discussion of plant performance on day today basis, collecting related feedback from internal customers, communicating subordinates and assure for the execution of corrective actions
Kra2 Plant Availability
Plan, Organise and monitor implimentatin activities for optimum plant availability in MechanicalDescipine as per target to meet production from cement mill as per requirement and satisfactionof internal customers.Coordinate the challenging of implementation / execution of maintenance activities Identification , Planning, & implementation of small modifications for better equioment performance.Proper coordination woth other departmets.Training to the workmen through workers development programmes and onsite training programmes for skill upgradation.Plannig and procurement of advanced good quality tools and tackles for fast execution of jobs.Daily monitoring of equipment health and maintaining records.Maintaining proper housekeeping and following good maintenance practices.Discussion on chronic problems.
Kra3 Cost Control
Plan monitor and control spares and lubricants inventory and manpower cost as per budget in mech maintenance activities in coal mill in order to optimize the maintenance cost. Prepare Budget for KILN 1&2 area.Monitoring expenditure with resoect to budget.Classification of most critical and less critical and general spares.Accordingly spares procurement from OEM and Reputed substitutensuppliers.Carry out life value analysis for high value spares.Inspection of materials from reputed suppliers as per OEM requirement for achievinglonger life of equipment.Monitor stores inventory reduction , standardisatin and optimizationMonitoring of contract cost comparing wth last year expenditure.Close monitoring on workers overtime.Planning odf spare parts and raising indent for procurement as per requirement.Identifcation of maintenance cost reduction parameters.KRA4 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.KRA5 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 system
- Developing and sustaining Model area in respective sections
100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programs down the level team
To 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.
