Job Description

Job Purpose

To maintain the equipments in AFR section and increase the reliability and availability by implementing best mechanical maintenance practices to meet the AFR consumption targets. Identify and implement improvement projects to optimize the AFR consumption while maintaining Group, Business and Unit safety standards and procedures in AFR section.

Job Context & Major Challenges

Job Context:
Gujarat Cement Works is one of the single largest cement plants with an installed capacity to produce 6.5 million tons of cement /annum which is self-reliant on power having captive power plant (92 MW) ,two D. G. sets of 6 MW each , Mines & Captive Jetty, employing approximately 792 people. It manufactures a range of premium grades of cement for Export & Domestic market and enjoys a reputation of giving value for money. It is one of the largest cement plant at a single location in the country for export & import. Gujarat Cement Works has opted for the Best World Class Technology equipment right from its inception and it also has the desalination plant of capacity 2000 Cu m/day and associated RO plant
The plant consists of 2 Lines, each having peak clinker production capacity of 8000 TPD.
The plant has a state of art technology featuring fuzzy logic, X-Ray analyzer and CEM SCANNER to ensure optimum production and quality. The technical knowhow and main equipment has been obtained from M/s FL Smith Ltd., Denmark. GCW is also equipped with the Roller press technology, which is one of the latest equipment in cement grinding process. The unit has also bulk Clinker/cement loading arrangement and Raw material unloading arrangement from ship at jetty in addition to bulk loading by bourses and packed cement dispatch by road . The unit has about 2700 acre of land for Mines, TPP, Plant & residential colony, has about 36 kms road, 18 kms boundary wall and about 604 quarters & public utility buildings.
At GCW unit, CPCB had given the approval that the Unit can consume / burn Hazardous Solid waste, Hazardous Liquid waste and Hazardous Liquid solvent waste in both Phase 1 and Phase 2 Kiln. By consuming / burning these hazardous material:
1. We increase our value and social accountability
2. We reduce the impact of such hazardous material on the environment
3. Reduction in consumption of Costly Primary fuel i.e. Coal
Job Challenges:
1. Handling of flammable and Hazardous Liquid and Liquid solvent material
2. Handling of flammable and Hazardous Solid waste
3. Uncertain material quality
4. Uncertain weight to volume ratio
5. Non availability of daily required material quantity

Key Result Areas

	KRA (Accountabilities) (Max 1325 Characters)	Supporting Actions (Max 1325 Characters)
KRA1	1. Availability of Liquid and Semi Solid firing system in Ph-1 and 2.	1. Maintaining the equipments by implementing best preventive maintenance practices 2. Effective job planning with SMP / SOP and close supervision 3. Inspection of equipments as per defined frequency 4. Eliminating the root cause of repetitive failures
KRA2	2. Availability of Ph-1 Solid waste firing system	1. Maintaining the equipments by implementing best preventive maintenance practices 2. Effective job planning with SMP / SOP and close supervision 3. Inspection of equipments as per defined frequency 4. Eliminating the root cause of repetitive failures
KRA3	3. Reduce Stores & Spares and Repair & Maintenance Cost in AFR Section.	1. Increasing the life of wear parts by implementing best lubrication practices 2. Increasing the life of equipment by following highest preventive maintenance standard
KRA4	4. Projects A. Commissioning of Shredder Circuit B. Commissioning of Ph-2 Solid waste firing circuit.	1. Proper activity and spares planning 2. Monitoring of activity as per Bar chart
KRA5	5. Safety A. Zero fatal and personal injury B. Provide training on HOT WORK safety module C. Safety observation Round D. No. of JCC prepared E. Carry out CFSA as per schedule. F. Report and Maintain the SAM G. Near Miss reporting	1. Daily safety talk 2. Continuous concealing for following safety rules and procedures 3. Frequent site rounds to ensure the effectiveness of safe working 4. Actively participate in drives which promote safety culture improvement
KRA6	6. System Improvements A. Compliance to why-why analysis B. Update AFR section equipment and BOM in SAP C. Preparation of AFR section Equipment checklist and update the same in SAP D. Participation in KMFA and WCM Circle team meetings. E. Kaizen Reporting F. To ensure timely closer of applicable NCs received in ISO/IMS audit	1. Daily review of SAP master data of AFR section 2. Participating pro actively in KMFA and Operating team meetings. 3. Reporting of all modifications through KAIZEN 4. Weekly review of IMS requirements and its compliance.

PF Mechanical (Kiln & Cooler)