Roll Shop Shift In-Charge - Raigarh

Position:

1. Job Purpose

To supervise and manage all roll shop activities during the assigned shift, ensuring timely preparation, grinding, inspection, maintenance, and supply of work rolls and backup rolls to the rolling mill. The position is responsible for maintaining roll quality, equipment reliability, production targets, safety standards, and optimum roll consumption.

2. Key Responsibilities

A. Shift Operations

1. Manage and supervise day-to-day roll shop activities during the assigned shift.
2. Ensure timely grinding, dressing, turning, and preparation of work rolls and backup rolls as per rolling mill requirements.
3. Coordinate with the rolling mill shift in-charge for roll changes and roll availability.
4. Ensure proper planning and execution of roll grinding schedules.
5. Monitor roll shop productivity and ensure minimum turnaround time for roll preparation.
6. Ensure availability of required rolls for uninterrupted mill operation.

B. Roll Grinding and Quality Control

1. Supervise roll grinding operations as per approved roll pass profiles and dimensional requirements.
2. Ensure correct roll diameter, crown, contour, surface finish, and roughness.
3. Monitor roll surface defects such as cracks, scratches, chatter marks, and thermal checking.
4. Ensure proper inspection of rolls before and after grinding.
5. Maintain roll history, grinding records, and roll consumption data.
6. Ensure proper identification, tagging, and traceability of all rolls.

C. Equipment Maintenance

1. Monitor the condition and performance of roll grinding machines, CNC grinders, lathes, and auxiliary equipment.
2. Ensure routine inspection and preventive maintenance of roll shop machinery.
3. Coordinate with the maintenance department for breakdown maintenance.
4. Minimize machine downtime through effective planning and troubleshooting.
5. Ensure proper functioning of measuring instruments and grinding machine accessories.

D. Manpower Management

1. Allocate duties to operators, technicians, and helpers during the shift.
2. Monitor manpower performance and ensure effective utilization.
3. Provide technical guidance and training to team members.
4. Ensure proper shift handover and communication.
5. Maintain discipline and coordination among shift personnel.

E. Safety and Housekeeping

1. Ensure compliance with plant safety rules and standard operating procedures (SOPs).
2. Ensure proper use of personal protective equipment (PPE).
3. Conduct toolbox talks and safety briefings.
4. Ensure safe handling, lifting, shifting, and storage of rolls.
5. Maintain 5S and housekeeping standards in the roll shop.
6. Report unsafe conditions, near misses, and incidents.

F. Documentation and Reporting

1. Maintain shift-wise roll grinding and roll preparation reports.
2. Monitor roll inventory and availability.
3. Maintain roll consumption and grinding loss records.
4. Prepare shift production and machine downtime reports.
5. Report abnormalities and critical issues to the Roll Shop Manager.
6. Ensure proper shift handover documentation.

3. Key Performance Indicators (KPIs)

• Roll grinding productivity.
• Roll preparation turnaround time.
• Roll dimensional accuracy and surface quality.
• Roll consumption and grinding loss.
• Roll shop machine availability.
• Reduction in machine breakdowns.
• Timely availability of rolls to the rolling mill.
• Safety compliance and zero accidents.
• 5S and housekeeping compliance.

4. Required Qualifications

• Diploma / B.Tech in Mechanical Engineering or equivalent.
• 510 years of experience in a steel plant or rolling mill roll shop.
• Practical experience in roll grinding, roll turning, and roll inspection.
• Knowledge of CNC roll grinding machines and roll measurement techniques.
• Knowledge of work rolls, backup rolls, roll profiles, and roll metallurgy.
• Good leadership, coordination, and problem-solving skills.

5. Technical Skills Required

• Roll grinding machine operation and troubleshooting.
• Roll profile and crown measurement.
• Roll surface inspection and defect identification.
• Knowledge of roll grades and hardness.
• Knowledge of grinding wheel selection and dressing.
• Knowledge of roll chocks assembly and bearing assembly.
• knowledge of Oil film bearings i.e Morgoil bearing functions and parts 
• knowledge of 4 row tapper roller bearing assembly and BEP measurements
• Measurements of chock liners 
• Hands on experience for use of inside and out side micrometers. 
• Knowledge of roll shop SOPs and safety procedures.
• MS Excel and shift reporting.

6. Key Responsibilities Summary

The Roll Shop Shift In-Charge is responsible for ensuring:

• Right roll at the right time.
• Correct roll profile and surface quality.
• Minimum grinding time and roll consumption.
• Maximum machine availability.
• Effective manpower utilization.
• Safe and efficient roll shop operations.