1) Job Purpose:
Write the purpose for which the job exists
Bauxite Handling and Red mud loading, stacking & transfer to different Cement plant). Raw Material (Bauxite) availability, production (Crushing to size less than 1 ), maintece (equipment availability), product (red mud) dispatch via railways, to utilize the resources in the most effective manner to achieve organizational production targets with respect to quality, quantity, cost and all statutory compliances.
2) Dimensions:
Mention quantitative or qualitative parameters that are relevant for the job and provide a better understanding of the scope and scale of the job.
Business Workforce Number
146Permanent workmen of department
120 Contract workmen.
Other Quantitative and Important Parameters for the job: Budgets/ Volumes/No. of Products/Geography/ Markets/ Customers or any other parameter
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Contract labor management
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Red mud management at railway siding
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Red Mud loading, covering
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Bauxite unloading at tippler
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Bauxite management at Bauxite shed
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Bauxite feeding, equipment availability and maintece and area housekeeping
3) Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business / Unit / Function / Department / Section
Hindalco Muri Alumina Refinery produces Smelter Grade Alumina as well as special grade Alumina processing Boehmitic hard Bauxite using Low and HighTemperature Digestion technology and split seed charge in agglomeration and new growth circuits in Precipitation area. The designed capacity has been increased to 4, 50, 000 TPY through various strategic expansions. Plant is designed for TAA in Bauxite 46. 5% and Silica 4. 2%. However Good Bauxite at Lohardaga Hindalco mines has got exhausted and TAA availability is between 3738%, Silica is between 4. 0 5. 0%. Normally plant design takes care of generated waste storage infrastructure. However, due to various external factor waste storage infrastructures that were not developed for fly ash storage, only Red mud (Bauxite residue) storage facility was enhanced by dry mud storage vertically in 2015. However, the red mud dump collapsed in April 2019, and technology failed. Now units have no storage facility for red mud, it is completely dependent on demand by cement industries who use red mud as raw material for cement manufacturing. Cement industries also use fly ash for cement manufacturing. So overall plant production capacity is controlled by red mud and ash demand by cement industry and quality of Bauxite available from Hindalco mines.
Following are the major challenges for Refinery operation:
- Bauxite quality Poor availability of good quality bauxite which has adverse impact on refinery operation like higher cost, processing of unproductive extra mud, higher specific consumptions of various raw materials and chemicals.
- Bauxite residue management Nonavailability of Bauxite residue storage yard, dependency on cement industries for consumption of red mud.
- Bauxite residue moisture management Cement industries need lower moisture
- Cost management Control manpower intake for housekeeping, ensure preventive maintece of all equipment as per requirement,
- Customer management Maintain product (crushed bauxite) size less than 1 more than 85%. Ensure wagon covering 100% during monsoon.
- Critical equipment management There are three conveyors that are single line equipment for bauxite handling Unit.
- Workmen competency Historically Muri unit is abiding by agreement with union that if one workman retires, his next keen takes the job irrespective of required qualification w. r. t contemporary business challenge. Unauthorized absenteeism is another challenge.
- Safety management Very high % of human interference required at many places in Bauxite handling unit. This is due to frequent cleaning activity required to maintain continual section operation. Mechanized cleaning provision needs to be deployed. Developing competency of workmen, infrastructure for reliability, people behavior are the great challenges.
- Contract management Manpower intake in bauxite handling unit is very heigh approx. 150 /day, Management of their daily record, safety compliance, statutory compliances are great challenge.
Key Result Areas
Supporting Actions Safety and Environment
- Implementation of Safety standard, Occupational health, and Environment standards across the Refinery to prevent accidents and protect environment,
- Implementation of structured training for workmen and staffs, contract workmen
- Ensure the compliance of statutory requirements for the unit w. r. t safety.
- Ensure all safety parameters are met for the unit.
- Implementation of E permit, BBSO, contractor safety management system
- Hazard & risk assessment of all activities
- Analyze accidents if any and direct preventive & corrective actions
- Propagate use of safe and clean work habits
- Implement OHSMPs and EMPs to improve safety and environment practices
- 2. Production Volume and quality
- Monitor resource for all operational activities for all material handling and process areas.
- Ensures the adherence of process control parameters. Drive efforts towards achieving maximum output by effective utilization & debottlenecking of equipment.
- Prepare performance report & coordinate maintece plans and provide input to ensure availability of equipment.
- Study chronic issues and analyze breakdown trends for improving availability and provide guidance.
- Implement operation strategies for production to support operational maintece of equipment.
- Inter & Intra departmental coordination to facilitate production planning & efficiencies. Review & monitor annual shutdown plan activities of RA1
- Plan Monsoon preparation activities of Bauxite yard management & Red Mud management with respect to operation & environment.
- Cost management
- Affectively utilize available heavy earth moving equipment to achieve maximum efficiency.
- Review of operating parameters & practices to ensure efficiency and ensure the adherence of process control parameters.
- Coordinate and interact between production and rest supporting departments to provide resources to achieve targeted efficiencies.
5) Job Purpose of Direct Reports: Describe the job purpose of the direct report/s to the job
Permanent Workmen:
Execution of the field activity. Maintain all schedule jobs and area housekeeping of Red Area1 Operation (Wagon Tippler, Bauxite Handling & crushing, and red mud loading, stacking & transfer to the different Cement to achieve targeted alumina production meeting cost, quality, OTIF, environment, and safety standards.
