PF Mines Maintenance - Nathdwara Cement Works

Job Purpose

To ensure availability and reliability of assigned HEMM or plant equipments or Loco to meet targeted production on daily basis by executing maintenance plan with quality maintenance. Utilization of resources to achieve the Departmental objectives, ensuring safety of perosns and equipment, ensuring all legal compliances, maintaining all required records.

Job Context & Major Challenges

Nathdwara Cement Plant was commissioned with the manufacturing capacity of 4.8 MTPA and clinker capacity of 4.81 MTPA. The first unit was installed in 1997 and second unit was installed in 2007. Grinding Unit, Neem ka Thana was commissioned in 2007.Limestone requirement of the plant is 4.5 MTPA. To meet the limestone requirement, limestone mines are spread over 724.7 Ha having deposits sufficient for around 50 years. Limestone crusher including wobblers having capacity of 1000 TPH, located inside the plant. Material is transported from mines to plant through dumpers.The Unit has three captive thermal power plants of 24 MW & 2X23 MW i.e. a total of 70 MW. WHRS of 23 MW and Solar Plant is also there.The Cement & Power Plant is located at strategic location on Highway Cement is more than requirement and 40% manpower is Land Sellers who got job in consideration of Land. The skill & competencies are very less. The attitude towards work and job is not very appreciating.Major Challanges

Major Challenages

To improve the competency level of operators and mechanics.Reducing cost of maintenance and breakdown of TippersTo save fuel (Diesel) & Lube and consumption of spares and reduce breakdowns of HEMM a ageing equipments

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

KRA1 Availability of Heavy Equipments for Mines Operations To ensure equipment availability as per targets.Proper planning of spare parts & scheduled maintenance based on OEM recommendations and also conditioned based monitoring.To reduce the breakdown of equipment to ensure availability for operationTo improve MTBF & MTTRMonitor preventive maintenance schedule.Liase with stores for spare parts availability.Monitor stock availability of fuel and lubricantsUtilisation of SAP/R-3 PM (Module) for history data.Take steps for upgrading of existing equipment.Interact with OEM for major problem & improvement.To save fuel (Diesel) & Lube and consumption of spares and reduce breakdowns of HEMM equipments.

KRA2 Cost Control

(Assist superior to control maintenance costs of HEMM, LMV, Cranes etc, to optimise cost of operation and maintenance.) To reduce the invetory of tippers as part of cost control exercise.Inventory analysis using various methods (VED, XYZ, FSN, etc)To reduce the HSD consumption on total material handling as part of cost control exercise.Engine, FIP & injectors overhauls and effective maintenance techniques in a phased manner.Control contractor & over time cost.Better maintenance practices through PM analysis or Why Why analysis.Monitor fuel and lubricant consumption.Standardisation of the equipment to maintain low inventory.Introduction of fuel efficient equipment (engines) Enhance the life of the major sub-assemblies by quality maintenance.Life value analysis.KRA3 100% compliance of Statutory and maintaining records Completion of all statutory recors timely for equipmentsAir receiver test, Brake test, Pollution test etc.To comply with the applicable statutesKRA4 System Implementation 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.Preparation of DPR report, MIS, M2 and M4 Notification in SAP on shift basis.Responsible to update QCDIP & LCM.KRA5 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.