Job Purpose
To carry out regular & planned maintenance & necessary modifications in Kiln, Work for optimization of Kiln, Ensure no breakdown should occur because of Instrument Failure.
Job Context & Major Challenges
Job Context:
UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. It is also one of the leading cement producers globally. The company has a consolidated capacity of 132.45 Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants, 1 Clinkerization plant, 27 grinding units and 7 bulk terminals, post the Century merger. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka. UltraTech, Rawan Cement plant started its Line 1 operation in early 90 s with the capacity of 1 MTPA, commissioned in March, 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March 2013, Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility, currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW, Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch, Germany for grinding limestone and coal, Kiln and cooler from L&T/FLS, Denmark, Combi-Grinding Cement Mill with Roller Press from KHD, Germany, Finish Grinding Slag Grinding Roller Press from Krupp Polysius, Germany, Cross belt analyser from Gamma Metrics USA for on-line analysis of Limestone, X-Ray analyser, Cem Scanner from FLS, Denmark. As the largest cement producer in India, we continually strive to play a key role in finding effective and responsible ways to preserve the environment - a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management, energy reduction, water conservation, biodiversity management, afforestation and emission reduction which are relevant to the cement industry. Major challenges Reduce the 20% break down in Kiln from Last Year. 100 % availability of equipment in above mentioned sections. Completion of project jobs within schedule time for increasing the productivity, better quality and lowest power. Zero accident. Planning to control the ideal inventory and maintain all spare parts.
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters) KRA1 Accountability:Plant Availability Supervise and coordinate for smooth, trouble free operation of instruments by providing maximum equipments availability in Cement Mill, Slag & Mixing section as per requirement and satisfaction of internal customer. - Analysis of stoppages report and organizing. - Corrective preventive actions with timely monitoring. - Plan & organize required resources for the job. - Coordinate maint. Jobs related to preventative, shutdown & modification / up-gradation . - Preparation of proposals for modification / up-gradation and take approvals. - Interact with OEMs / Consultants for typical plant maintenance problems. - Facilitate and reorganize required manpower within the existing. manpower available within the unit. - Meet regularly internal customers to take feed back & communicate to concerned for corrective action. - Extending help required to internal customer. KRA2 Cost Control & Optimization: Monitor and control the execution of maint. Jobs of the section as the budget allocated to keep the cost under control by effective utilization of resources. - Preparation of budget - Monitor consumption of resources with respect to budget. - Carry out why-why analysis to prevent recurrence. - Studies Provide interlocks for minimizing idle running of equipments. - Standardization of Instruments in the section. - Review material requirements and inventory. - Control contractor cost & overtime. - Alternate material / design change development and trials. KRA3 Calibration: Organize timely calibration of field instruments for measurement accuracy to reduce losses and improve to customer satisfaction. - Monitor and organizing calibration of instruments as per the schedule. - Coordinate with stores for calibration certificates. - Organize the baseline of instruments to know the test status. KRA4 Plant Improvement /Modifications: Study the existing systems and process requirements and identify, improvement/ modifications and ensure implementation of approved proposals for completion in time / as per for continuous improvement in the section. - Collection & analysis of Data. - Identify improvement / problematic areas. - Brainstorm for alternatives. - Discussion with superiors OEMs - Review of available resources - Formulate proposal & seek approval - Monitor implementation progress - Plan for revisions of specifications / drawings KRA5 Environment & Safety: Monitor & carryout all the activities required to maintain good house keeping & safety standards of section. - Review the jobs / systems - Insist for following safety systems/safe practices. - Guide / interact for effective implementation. - Impart training to workmen/contract workmen. - Identification & rectification of unsafe points/leakage points. - Regular checking of level sensing instruments. - Regular checking of tools & tackles. - Analyze accident/near miss cases. - Carryout safety/environment audits. - Regular checks of dust collector solenoids. - Monitor working of pollution control equipment. KRA6 System Implementation: Organise, and implement ISO/ OHSAS/SA 8000 and WCM systems in the section through involvement of Team members for improvement of sections working & quality standards. - Identify and execute improvement studies and kaizen. - Identify & get rectify. -Abnormalities. -Spillage/leakages. -Unsafe conditions/practices. - 5S activities. -Points emerged in campaigns.. - Execute implementation plan for - Quality improvement objectives. - Improvement of WCM practices. - Internal customer rating improvements. -ISO system improvement. -Statutory compliance. - Improvement of OEE/MTBF/MTTR -Elimination of MUDA. - Prepare/present weekly/monthly WCM presentation. - Development & implementation. - Update WCM activity boards. - Develop Model area. - Create awareness in team members. - Visual controls development & implementation. - Monitor working of pollution control equipments.
