AET Mbr Ops

• Job Purpose: Write the purpose for which the job exists (in 2-3 lines)
  
  

Lead, Plan, organize, execute, and drive operations in Refinery 3, focusing on continuous improvements in production, cost, quality, while ensuring high-quality product delivery that exceeds customer expectations and complies with safety, regulatory, and environmental standards as per P&B/ Business target through flawless daily work management and a culture of excellence in AET and ensure effectiveness of cross functional collaboration in DMT.

Ensure that the process control system are in place and align it with the overall goals of the organization. Providing the roadmap for the future development and ensuring compliances with industrial standards and regulations

To deliver high quality products that meets/exceeds external customer expectations within industry standards with cost efficiency and timely delivery.

• Dimensions:
  
  

Business/SBU/Unit Revenue

Revenue : 52,000 Crs (FY-24)

EBIDTA : 2400 Crs (FY-24)

Business Workforce Number

MG:630

Staff: 410

Worker: 900

Contract: 5000

Unit Workforce Number

MG: 420

Staff: 325

OG: 900

Workmen: 4000

Function Workforce Number

Staff: 132 (Management), 95 (LMS)

Company Workmen: 433

Contract Workmen: 659

Total Strength: 1319 Nos

Department Workforce Number

Staff: 10 (Management), 13 (LMS)

Company Workmen: 60

Contract Workmen: 120

Total Strength: 203 Nos

Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter

Budget as per P&B – Rs. 149 Crs

Number of units: 1

Volume: Cathode: 198000 MT

• Internal Customer: 150000 MT
• Sale: 48000 MT
  
  

Nos. of By Products -

• De-copperised Slime – 1000 MT
• Liberator Cake – 600 MT
  
  

Expenditure –Capital Budgets: 60 Cr,

Research/Technology Development -

• Cell Prototype research & technology Development
  
  

Critical Equipment -

• High Speed EOT Cranes (2 Nos.)
• Rectifiers (4 Nos)
• Cathode stripping Machine (2 Nos)
• Anode Preparation Machine (1 Nos)
• Spent Anode washing Machine (1 Nos)
• Electrolyte Circulation Pumps (4 Nos)
  
  

No of Confined Space – 16 Nos

No of Total Work permit – 240 / month

No of Special work Permit – 180 / month

No of Haz Waste Management -

• Cu – As Sludge (30 MT)
• Liberator Cake (600 MT)
  
  

Power Consumption: 79 million KWh

No of SOP/SWI: 95 / 120

No of Trailers managed: 3 nos. per day (@24 Hrs basis)

• 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
  
  

Job Context

Birla Copper has a copper smelting and refining complex at Dahej producing copper cathodes, cast copper rods, precious metals such as gold silver and selenium, fertilizers, and other biproducts such as sulphuric acid, phosphoric acid etc. in multiple plants with different technologies requiring diverse competencies. There are approximately 1500 employees, across functions at the Dahej unit of which about 350 are in the management cadre. This role is responsible for the operations of Refinery 3. Anodes of 99.5% purity supplied by Smelter 3 is processed to produce cathode of LME grade A of 99.99% purity for sale in the market or supply to CCR plant for further processing as copper rod. Cathode, being registered under London Metal exchange requiring stringent quality control. The key aspect of this role is to ensure production of cathodes as per budgeted quantities with required quality specifications. Implementation of norms of relevant, quality standards and health, safety environment norms. It involves driving continuous improvement of efficiencies through process improvement and upgradation of skills.

• This role is responsible Sustainable Operation of Refinery 3 by finding creative solutions to long standing issues and recognizing AET / DMT team members for good work. The most critical element of the role is achieving desired product quality while meeting production target fulfilling LME compliances.
• Ensuring the efficient and effective planning of the Refinery by monitoring and controlling processes, analyzing production data, MIS of inward, outward and WIP and implementing process improvements. Optimize plant performance, product quality, and safety while minimizing costs and environmental impact.
• Tracking of inventory of Refinery at various production stages and ensuring that it is within targets, reconciling with monthly financial records.
  
  

Major Challenges

• Refinery is highly complex, automated plant with synchronized operations of interlinked machines with a centralized communication management system. To ensure smooth operation & maintenance, it requires advanced knowledge in all the operational areas of Process
• The products are directly used in end applications and hence critical to customer and their applications. Knowledge of Refinery Operations, Efficiencies and requirements of Quality Parameters is very important to understand and execute refinery operation as required to produce LME Grade Product.
• Compliance to stringent quality standards.
• Meeting stringent Product Quality of FG with varying sources of Raw material (concentrate).
• Adhere to Legal and environment compliance with respect to emission & zero discharge of air, oil, and water i.e., conservation natural resources, energy etc.
• The entire plant network, communication system, PLC, logic-based hydraulic system, requires high level of analytical skills during troubleshooting of the problem.
• To sustain lowest cost producer of Refinery.
• Process Optimization :
  
  

Quality of anode varies on account of variation in quality of concentrate affecting quality of final cathodes sold as finished goods and acceptance of production in domestic and export market. Rigid control is maintained on process parameters, reagent addition and other operating practices to avoid impurity build-up in solution, nodulation in cathode surface.

• Equipment Reliability :
• Preventive Maintenance : Equipment's including Slime area pumps, Filters, Autoclave, RFT, Commercial Rectifiers area equipment's meets PM compliances, statutory compliances.
• Unplanned Downtime : Managing and mitigating the impact of unexpected equipment failures or breakdowns during shift hours, which can lead to costly downtime and reduced productivity.
• Safety Management :
• Risk Mitigation : Identifying and managing risks associated with Bismuth area, CRP plant, Cell house, circulation system and other hazards inherent in the Refinery process.
• Compliance and Training : Ensuring all personnel are properly trained and compliant with safety regulations, and maintaining a culture of safety awareness.
• Cathode Quality Control :
• Cathode quality Consistency : Maintaining the consistency and quality of the Electrolyte and Cathode quality which is crucial for optimal Refinery and CCR performance. Variability in concentrate quality can affect process stability and efficiency.
• Performance Variability : Addressing and correcting issues related to Cathode slime and electrolyte performance that could impact the overall efficiency of the Refinery process.
• Data Analysis and Process Monitoring :
• Interpreting Data : Analyzing process data to make informed decisions and adjustments. This involves understanding complex data sets and trends to proactively address potential issues.
• Real-Time Monitoring : Ensuring real-time monitoring systems are functioning correctly and providing accurate information for immediate decision-making.
  
  

Balancing these challenges effectively is crucial for achieving operational excellence, ensuring safety, and maintaining the overall efficiency and reliability of the Refinery process.

• Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)
  
  

Key Result Areas

Supporting Actions

Safety & Workplace Management

• Ensure that all changes are made through MOC system, HAZOP / PSSR / HIRA is conducted for operation team, and all identified hazards & unsafe behaviors.
• Drive strategic improvement initiatives under the guidance of AET leader and ensure all safety standards implementation like PTW & LOTOT, work at height, chemical safety, and confined space.
• Implement procedures & plans, for compliance through effective BBSO, PI and identification unsafe act and unsafe condition.
• Identify health hazards that arise out of occupational, design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
• Drive Kaizen and other improvement initiatives for greater sustainability of operations.
• Maintain workplace in order with respect to all Sub-areas (Level of 5-S).
• Ensure the implementation of Gas cylinder, HIRA standards as per SAQ in Refinery-3
  
  

Daily Work Management

• Drive flawless daily work by undertaking following:
• Implementation of DMT members excellence standards across the Area by arranging daily meeting at Control room
• Achievement of monthly, quarterly and annual P&B targets of the assigned Area in terms of quantity & quality
• Evaluation of Daily Performance Indicators (DPIs) of the team.
• Set & communicate clearly defined KPIV & KPOV (Key Performance Input / Output Variables) to DMTs with all the related costs.
• Undertake Abnormality Identification in DMTs through Root Cause Analysis and address unfavorable deviations through countermeasures (Kaizen, SPL, Visual Controls, Mistake proofing, Change in SWI, etc.)
• Define work priorities, execute plans on day-to-day basis pertaining to SQCDPM, and review Root Cause Analysis of any unfavorable deviations in last 24 hours.
• Define Model areas / machines devoid of unwanted items and make abnormality Identification (8 types) & redressal as a continuous process in all DMTs (5S & Kaizen).
• Oversee Daily Operations and Production : Manage daily operations, production, and maintenance, making decisions in alignment with the AET leader's guidance.
  
  

Continuous Improvement

• Ensure continuous improvements using problem solving tools (RCA, OPL, Kaizen etc.)
• Drive QC, FI (Focused Improvement) Projects and other improvement initiatives to improve productivity & cost efficiency of the Area.
• Create value through waste elimination, optimum resource utilization, productivity enhancement, etc.
• Minimize set up time for every change of product and revive the process to normal operation conditions..
  
  

Asset Care & Equipment Reliability

• Undertake Root Cause analyzes of breakdowns of Bismuth, CRP slime and circulation system to minimize process disturbance and production delays.
  
  

Process Care & Quality

• Monitor & control process parameters to ensure smooth operations and undertake immediate corrective action in case of any deviation.
• Keep Cost of production within budget by following measures:
• Minimize rejection , deviation & rework by ensuring delivery of products as per quality & customer requirement.
• Monitor and explore opportunities to bring down variable cost.
• Ensure robust weatherproof packaging so that the product reaches customer with intended aesthetics and quality.
• Ensure implementation of finest process care practices across the AET leader and monitor its effectiveness in coordination with PBU, to achieve higher efficiency and quality.
• Achieve the targeted production as per quality specifications benchmarked with international standards and changing customer needs.
• Ensure adherence to laid down processes & practices pertaining to manufacturing without any deviations, to attain consistent product quality.
• Take part in execution of Major Initiative Projects for maximizing the premium grade production. (i.e. Digitalization, Annual shutdown planning and execution etc.)
• Drive the culture of structured problem solving by ensuring implementation of FI, Just Do It, and any other project, which is derived from chronic issues.
  
  

Customer Centricity

• Meet and exceed internal & external customer expectations, adhere with service level agreements (SLAs), and implement action plans based on ICSI, customer feedback & surveys.
  
  

Capability Building & People Engagement

• Develop Skillset of DMT members and maintain optimum Skill inventory.
• Job Purpose of Direct Reports: Describe the job purpose of the direct report/s to the job (in 2-3 lines for each report)
  
  

Each direct report plays a crucial role in supporting the overall efficiency, safety, and reliability of the refinery process. Their responsibilities are designed to ensure that the cell house smoothly, equipment remains in good condition, and all safety and quality standards are upheld. Coordination among these roles is key to achieving the objectives of the refinery operation and meeting organizational goals.

• Field Operators (Circulation)– 04 nos in each shift – reported any abnormalities related to Cell house, Liberator area, anode yard, cathode yard, basement of cell house
• DCS operator – 07 nos in each shift – reported abnormalities related electrolyte temperatures, ECP area, Pump area, slime area Also timely supplying effulent to Bi and CRP plant.