Job Purpose

To plan, manage, monitor, guide and review the functioning of total materials management, system consisting of Raw material (corrective materials) & S & S including capex procurement, stores management, inventory management, work contracts management, scrap Management, and in- bound transportation management of various materials, which are in scope of Unit,in line with the business requirement and company objectives with a view to optimise cost, quality and delivery within the targeted budget to meet the customer and supplier's expectations automating / digiting various processes.

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. The company has consolidated capacity of 138.39 Million Tons Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 29 grinding units and 8 bulk terminals.

Baga Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Jaiprakash Associated Limited in the year 2017. Baga Cement Works is located at around 155 Km from Chandigarh, 67 km from Shimla and 37 km from Bilaspur (HP). The nearest National Highway is NH-88 which is 17 Km from the plant. The plant has 10,000 TPD clinker production capacity & 250/300 TPH OPC/PPC cement grinding capacity. The preheater consists of four strings, each with 6 stages of LP cyclones, with two pyroclones supplied by M/s KHD. This is a unique feature of this cement plant due to which the plant operates at lower heat and electrical energy. The preheater has a height of 155 mtrs, with top floor at 135 mtrs. The preheater has been constructed out of tubular steel structure.

The Cement Plant is based on lime stone deposits in Baga – Bhalag hills which are adjacent to plant area. Limestone requirement of the plant is around 15000 TPD. For raw material grinding, two vertical roller mills of 420 TPH each have been installed with a C.F. Silo having a capacity of 24,000 MT.

The unit is equipped with state-of-the-art pollution control systems, and operating emission norms are much lower than the permissible standards of 30 mg/Nm3. Two continuous ambient air quality monitoring stations have been installed which are hooked up to CPCB and PCB and transmit real time data's.

For emergency electrical power, 8 x 1800 KVA, DG sets have been installed.

The township for the plant is located near the plant and has a residential complex for 300 families. 10+2 school and 30 bed hospital has been built. For transporting clinker and cement from plant a fleet of about 4000 trucks have been engaged.

Major Challenges

Ensuring timely availability of Raw materials, Packng bags, Fuel, Consumables, Stores & Spare materials at a competitive price and of acceptable quality to meet manufacturing targets and fluctuation in cement demand as per marketing requirement.
Cost reduction of major inputs.
Work with unit logistics team to increase back hauling between in-bound and out-bound logistics.
Reduction of inventory of Stores & Spares as well as Raw material/Fuels.

To procure Furnace Oil at an optimum cost in the wake of surging prices of Crude Oil & other Petroleum products.

To maintain optimum stock considering the limited storage space.
To prepare long term strategic planning for Raw material availability and judging local sensitivity.
Finalization of long term rate / running contracts for all regular consumables and services.
To ensure statutory and safety compliance.
To check, re-negotiate and approve Comparison sheet submitted by associated Grinding Unit team having value more than 50,000.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 Procurement of Materials

Planning and procurement of materials including Raw Materials, Stores & Spares, Lube Oils, Fuel Oil, services/repairs at optium cost for smooth plant operation which is in the scope of Unit as per DOP.

Coordinate and submit the Unit requirement of packing bag, fuel, imported raw materials and other materials which are in the scope of CPC. Formulate strategies for long term and short term contracts for materials having value < 12 lakhs per PR, in line with annual budget.Ensure development of Purchase Plan and Budget for the unit by interacting with the process owners/decision makers and capturing way forward including planned consumption of raw materials and consumables for the year which are under the scope of Unit's responsibility.

Timely submission of requirement of material to the CPC for the material under the scope of CPC including packing bag, fuel, grinding aid etc.

Ensure timely procurement/ supply of all items of specified quantity at an optimum price to achieve budgeted production targets.

Review data on purchasing lead times, no. of follow-ups with supplier, etc. and recommend course corrections.

Review and refine commercial processes to improve the process of raising purchase requisitions, receiving approvals, tracking purchase orders, vendor registration, vendor evaluation, and vendor database creation and management as well as for Purchase Order processing, tracking, payments, etc.

Decide corrective/preventive action for procurement.

Coordinate with CPC for the timely placement of order and resolve queries.

Conduct store/purchase meeting with all the stakeholder of the unit for bring improvement in inventory management.

KRA10 People Management & Development

To build & sustain a conductive work culture within department to improve productivity, growth & improvements in department performance for overall objective of unit along with motivating employees to institutionalize for bring innovation, creativity, best practices to replicate in the Unit by effective management of people for development of them

To identification of common training needs of team for building competency for current and future requirement of organization.
Ensuring Job rotation inter & intra-departmental for all-round development of team members.
Optimisation of manpower by giving opportunity of Job Rotation, Enriching & Enlargement of Jobs time to time along with recommending for internal or external training for skill behavioural/productivity improvement.
Empowering team to function independently, boost & maintain employees moral and motivation through employee wellness and wellbeing initiatives within department and having participative culture.
Prepare action plan based on Team Vibes Results direct reportee or rollout reportees to enhance engagement level of team.
Identifying successor for next role & groom team members in this direction.

KRA2 Inventory Management

Keep the inventory level at optimum level with in target and further keep improving without affecting plant performance (including furnace oil, / /raw material etc.).
Inventory for fuels & packing bags as per guidnece of CPC.
Plan & monitor management of project equipment, bulk materials, fuels etc. by coordinating with transporters & handling contractors.
Review timely receipt, inspection, GRN processing, storage & preservation of materials.
Review stores accounting and reconciliation of materials.
Monitoring inventory level for all critical items and recommend corrective action in case of deviation.
Plan, strategize and monitor timely disposal of scrap & waste.
Implement Optimum /restricted purchase concept.
Coordinate with user departments for identification of surplus/obsolete items & disposal thereof.
Identification/maintenance of common ideal items between group units.
Continuous interaction & coordination with users & vendors for better quality of services.
Coordinate stocking of packing bag and fuel with the technical dept for timely unloading of material.
Bench marking of inventory level with group units.

KRA3 Scrap/Waste disposal as received from Plant.

Selection of scrap disposal by E-auction agencies and monitor the performance of the scrap sell.
100% legal Compliance in case of hazerdeous category scrap.
Compare the sale price with group unit to get better realisations.
Timely disposal of all category of scraps.

KRA4 Cost-effective commercial management

Drive cost-effective purchasing through value engineering, benchmarking with other Units. (< 12 lakhs)

Foresee seasonal events to identify market factors which may impact availability and/ or cost of materials and services and develop mitigation plans.

Formulate strategies for negotiation.

Define checks and balances to minimize risks from vendors by developing norms/ code of conduct and ensuring complete compliance with regulations/ statutory requirements.

Arrange vendor meet for exchange of information/ideas

KRA5 Work contract management

Ensure timely availability of all services needed for uninterrupted plant operations, house-keeping, preventive /break-down maintenance at optimum cost, within the required time frames and with all statutory compliance.
Refine contractual clauses with regard to performance standards and track vendor performance against set standards for course corrections/actions.
Ensure rigorous evaluation of vendor prior to award of contract from a commercial as well as a technical perspective.
Ensure all required parameters are being met, understand component costing, and provide inputs on refinement, where required.
Ensure implementation of CSM procedure and guidelines in the unit.

KRA6 Compliance, System improvement and

SHE (Safety, Health & Environment) along with Sustainability initiatives

Establish & identify the areas for improvement in terms of cost, quality, services & systems.
Implement Standard Operating Procedures (SOPs) and Delegation of Authority (DOA) to streamline the entire process chain for Commercial from purchase requisition up to approvals.
Initiate improvement programs / projects like VMI, Rate contracts etc.
Review Just in time (JIT) supply for raw materials, consumables & fast moving items.
Ensure compliance for procurement, storage and handling of hazardous materials.
Review the compliance of statutory & safety requirements for the storage of hazardous materials, disposal of scrap & waste.
Ensuring 100% implementation of all applicable safety standards in department with target of zero injury and no hazard to men, machinery, environment and health of employee deployed in respective department.

KRA7 Compliance, System improvement and

SHE (Safety, Health & Environment) along with Sustainability initiatives

To ensure whoever is working in department from top to bottom should aware about I know my job, I know the hazards associated with my job and I applied control measures & I escalate to my senior
Implementation, adherence of Progressive Consequence Management and taking needful action.
Effective contribution in respective safety subcommittee, be visible felt leader and sharing views in apex safety meeting for building and inculcating strong culture of safety.
Ensuring self and team timely conduct CFSA or SO, reporting of any incident or accident along with taking analysis and corrective actions in respective systems. Completion of all Incident Investigation within timeline.
To create awareness on well-being and environment aspect for sustainabile among team and self
Motivate and bring new technology, innovation way of saving natural resources like water, power, controlling on air pollution etc by ways of sustainable initiatives
Ensure to completion of abnormalities observed and reported in daily walk through across department.
Ensure time bound action for closing out for audit (FPSA,SPSA,TPSA, internal and external Audits) findings before target date and compliance of all applicable RCN/BCN recommendations.

KRA8 System Management:-

(Coordinate, organize & monitor effective implementation of IMS and other systems in the department for improvement of productivity and creating safe work culture)

To facilitate department activities to implementation, sustain and continual improvement of internal & external customer satisfaction score, developing & drive maintenance strategy along with autonomous maintenance, visual development, knowledge upgradation, process improvement.
Ensuring respective assigned team performance & monitoring WCM (ABOF) MIS regular for 100% compliance against various WCM audits/assessments (5S,BCE, Hygiene etc.) & timely evaluation of Kaizen & suggestions in system.
To ensure timely compliance & implementation of IMS & other standards requirements like creating awareness among team on systems policy, implementation, document verification for zero non-conformity or OFIs in internal & External system audits/assessment. Provide Internal & External audit responses in time.
Mentoring & driving associated KFA & GRT as per the ABOE framework & CWCM guidelines.
Encouraging team for improvement projects & Kaizen to enhance performance & productivity along with bringing and adopting new technology projects & its development actions.
Ensure implementation of initiatives identified by the corporate office.

KRA9 People Management & Development

To build & sustain a conductive work culture within department to improve productivity, growth & improvements in department performance for overall objective of unit along with motivating employees to institutionalize for bring innovation, creativity, best practices to replicate in the Unit by effective management of people for development of them

Guiding team of SMART and differentiating Goals Setting aligning with Unit and Business targets, time to time review performance and giving or seeking quality real time constructive feedback on performance appraisal and other areas. Rewards and recognition without any biasness.
Developing Team for multiskilling for next role through The 70:20:10 Model for Learning and Development.
Having regular communication that count with maintains transparency for top to down communication (mentoring, coaching, counselling, recognition etc.).
Developing interpersonal skills, maintain discipline, adhering ABG Values and systems, handling and resolving grievances and good rapport building with other colleagues within function or cross function.
Encouraging them for taking lead in Unit, Business or Group level projects and contribute for growth.

DH Materials