Job Purpose
Planning, monitoring and directing for availability of CS2 furnace to CS2 production function. Development of systems for improvement in furnace dishing, unit cleaning ,graphite electrode and refractory brick replacement, safety, environment and input cost.
Job Context & Major Challenges
Birla Cellulosic is a situated on the banks of river Kim in the agricultural belt of Hansot- Taluk in Bharuch district of Gujarat. The project was conceptualized in the year 1994 and was fully commissioned in 1998. Brown field project was fully commissioned in 2009. The unit has a consent capacity of 348 TPD of Viscose Staple Fibre and is the most modern Viscose Staple Fibre producing unit of Grasim’s pulp & Fibre business. It also has 65 TPD Carbon-DI-Sulphide (CS2), 350 TPD of Sulphuric Acid, 2 x 15 MW, 1 x 10 MW Thermal Power Plant and other auxiliary plants like Water Treatment, Demineralization, RO & Effluent Treatment Plant etc. Birla Cellulosic has entered into business at a time when globalization is on its peak and quality requirements of the customers are changing very fast.
Major Challenges
All above objectives are to be achieved in an old plant with more equipment life and various limitationsAssociated with an old plant like improper layout, old equipment & illiterate workforce. This often requires development of new systems and upgradation of existing ones. Graphite Electrode and refractory bricks inventory for CS2 manufacturing requires more involvement during deashing activity. System improvement and upgradation to avoid lapses during manual material handling and working in confined space. Charcoal based CS2 plant having more trouble shooting activities like furnace shell temp high,red hot, brick and electrode failure, sulphure seepage from Bottom Electrode. Gas and CS2 leakages leads to incident and create unsafe working area. Enhance the safety culture and achieve desire result and set target.Unit Specific Challenges
- Dealing with highly gaseous environment and hot area.
- Very old technology - absolute technology - Maintenance and energy consumption
Position Challenges
- Producing benchmark product due to the varying Quality of Charcoal availability
- High energy consumption in the process due to usage of old technology
- Reduction of Fugitive emission in the work environment which poses health hazard
- Maintaining of consistent quality with the existing input materials
- Carrying out rehabilitation, repair and technological innovations in running plant - sustaining production and quality without sacrificing safety and environment
- Competency of contact people to carry out the tasks and activities
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.
- Monitor production status and ensure timely delivery.
- Assist in new product development and enhancements.
- Ensure that finished products meet quality standards and customer specifications.
- Determine equipment, materials and manpower required to complete production.
- Ensure spares and raw material Inventory are available as per the desired stock levels to ensure no disruption in production activities
- Monitor and analyze Downtime with Root cause to reduce its impact on Cost, Quality and Delivery
KRA2 Safety & Environment 1. Developing SOPs, JSA, HAZOP & SMP and periodic review for its upgradation
- 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)
- Assist plants in leading Process Hazards Analysis (PHA) for major risk projects by providing expert support in PHA methodologies.
- Provide support for risk scenarios requiring further assessment post PHA review as requested by plants.
- Support PSM Excellence implementation. Identify needs required to comply with PSM requirements.
- 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.
- Coordinate Safety Alerts and other company wide initiatives for their respective plants.
KRA3 Change management 1. Lead Continuous improvement culture among team members to deliver excellence in operations
- Ensure ABG Operational excellence guidelines are adhered by continuous training, implemented and review by using the RADAR framework of ABG
- Identify opportunities for joint improvement projects among departments, vendors and suppliers through CFTs
KRA4 Project 1. Ensure implementation of CAPEX within time lines and budgets
- Ensure Onsite and offsite quality inspection of incoming materials to ensure the standards are met for quality parameters
KRA5 Planning & budgeting 1. Adhering to approved P&B and update of the progress made
KRA6 Customer centricity 1. Managing customer complaint in consultation with CTS
- Schedule visit to customer to understand, learn and act on feedback and complaints
- Share time MIS reports as desired by internal and external customers
KRA7 People Management 1. 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
- Develop line managers into people managers to handle day to day grievances with utmost sensitivity
KRA8 Regulatory compliance 1. Ensure all the relevant regulatory compliances applicable to the operations are adhered to
- Participate in periodic regulatory compliance audits from external and internal parties to continuously improve systems
