Job Purpose
Producing and delivering of the desired Quantity & Quality of Fiber by effectively utilizing the available resources at optimal cost
Job Context & Major Challenges
Birla Cellulosic is the latest unit in Groups Pulp & Fibre Business established in 1998 with latest state of the art technology comprising of DCS control and certain imported equipments. The designated capacity was 63875 TPA. Post-expansion, this will now be scaled upto 133955 TPA.
Consequently, it is expected to produce best quality of VSF in the group with consistency and at lowest cost of production and establish benchmarks with the group. The Unit meets the requirement of fibre in both domestic and export market. Post-expansion, a 25 MW extraction mode captive power plant having interdependency with VSF operation is integrated with zero tripping tolerance. There has been continuous improvement on all fronts viz quality, safety, production, productivity, product grades, consumption ratios, environmental aspects etc. These are to be sustained and improved further for providing a competitive edge to the business. Viscose preparation is a chemical process and it involves a sequence of operations. Few important unit operations are: Alkylation, Xanthation, Filtration, de-polymerization, de-aeration , Refrigeration & use of catalyst etc. Control of various parameters in each operation in narrow band is required to maintain standard quality of the final product. It is also required to update the old technology to improve quality product, reduce cost of production, energy conservation & maintain safe work environment etc. Major Challenges Position Challenges: Water consumption in the process is high which would pose challenge during bad monsoon Carrying out rehabilitation, repair and technological innovations in running plant - sustaining production and quality without sacrificing safety and environment Resistance by the Collective bargaining units about bringing technological changes Unit specific Challenges: Machine 1 & 2 were developed in house, its very old technology - which limits productivity, quality and cost optimization Machine 1 & 2 doesn t have Digital Control System (DCS) which impacts manpower cost and process controls. Line workmen technical competency is not at the desired level due to their current qualification Quality of fiber produced in line 3 is superior compared to 1 & 2 hence effective bargain with customer to accept product from line 1& 2 is a challenge Producing benchmark quality fiber by using in house pulp is a challenge High energy consumption in the process due to usage of old technology Maximizing CS2 recovery from the current level is a challenge due old technology Reduction of Fugitive emission in the work environment which poses health hazard Maintaining of consistent quality with the existing input raw materials
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters) KRA1 Production Planning & Control 1) Plan work flow and schedules for production departments. 2) Monitor production status and ensure timely delivery. 3) Identify delays and accordingly adjust schedules to meet deadlines. 4) Assist in production risk assessment and mitigation activities. 5) Provide excellent customer service and ensure customer satisfaction. 6) Evaluate current production processes and recommend improvements. 7) Assist in new product development and enhancements. KRA10 People Management Ensure employees are aware of their roles and responsibilities and deliverables Create an enabling environment to discuss and share people issues at workplace Identify and facilitate appropriate training of competency gaps with the help of HR department Encourage and model the recognition culture at workplace Ensure Safety and Environment awareness among employees and training wherever required Develop line managers into people managers to handle day to day grievances with utmost sensitivity KRA2 Production Planning & Control 8) Conduct daily meetings to keep track of production schedules. 9) Ensure that finished products meet quality standards and customer specifications. 10) Determine equipment, materials and manpower required to complete production. 11) Resolve production issues and escalate unresolved issues to management promptly. 12) Assist in employee hiring, training, performance evaluation, retention and termination activities. 13) Ensure spares and raw material Inventory are available as per the desired stock levels to ensure no disruption in production activities 14) Monitor and analyse Downtime with Root cause to reduce its impact on Cost, Quality and Delivery KRA3 Regulatory compliance 1) Ensure all the relevant regulatory compliances applicable to the operations are adhered to 2) Participate in periodic regulatory compliance audits from external and internal parties to continuously improve systems KRA4 Safety & Environment 1) Developing SOPs, JSA, HAZOP & SMP and periodic review for its upgradation 2) Lead Process Safety Management (PSM) program implementation improvements through sharing and facilitating best practices among different plants and by creating the best means and/or channels for communications to serve this purpose. 3) Provide training to employees and contractors (as required) to assure understanding and compliance with Process Safety Standards and requirements of local process safety requirements. (PSM/RMP programs) KRA5 Safety & Environment 4) Assist plants in leading Process Hazards Analysis (PHA) for major risk projects by providing expert support in PHA methodologies. 5) Provide support for risk scenarios requiring further assessment post PHA review as requested by plants. 6) Support PSM Excellence implementation. Identify needs required to comply with PSM requirements. 7) Assist the plants in their procedure development and provide direct support to their implementation efforts of new and existing standards and local process safety requirements 8) Participate in Process Safety Event investigations/root cause analysis to provide guidance to all plants. In conjunction with site management teams, track progress of corrective actions where business wide issues are identified. 9) Coordinate Safety Alerts and other company wide initiatives for their respective plants. KRA6 Change management 1) Lead Continuous improvement culture among team members to deliver excellence in operations 2) Enable project based problem solving teams at workplace to promote team excellence 3) Ensure ABG Operational excellence guidelines are adhered by continuous training, implemented and review by using the RADAR framework of ABG 4) Identify opportunities for joint improvement projects among departments, vendors and suppliers through CFTs KRA7 Project 1) Ensure implementation of CAPEX within time lines and budgets 2) Ensure Onsite and off site quality inspection of incoming materials to ensure the standards are met for quality parameters 3) Review of spares drawings and piping layout 4) Ensure completion of process improvement projects within a specified time frame while achieving a cost reduction goal. 5) Provide management with project status updates, feedback, and appropriate reporting on key responsibilities and objectives. KRA8 Planning & budgeting Adhering to approved P&B and update of the progress made KRA9 Customer centricity 1) Managing customer complaint in consultation with CTS 2) Schedule visit to customer to understand, learn and act on feedback and complaints 3) Share time MIS reports as desired by internal and external customers
