Executive- Operations(Production)

Roles and responsibilities:

1. Production Planning & Target Achievement

• Execute daily production plan for Grinding and Calcination as per production requirement.

• Ensure achievement of daily, shift-wise and monthly production targets.

• Plan raw gypsum feeding, grinding and calcination according to silo levels and downstream requirements.

• Coordinate with Dispatch, Packing and other production sections to maintain continuous plant operation.

2. Grinding Section

Responsible for operation and monitoring of:

• Crusher

• 4-Roller Mill / 6-Roller Mill

• Screw Conveyors

• Bucket Elevators

• Rotary Valves

• Feeding Systems

• Blowers

• Dust Collection Systems

• Gypsum Storage Silos

Key responsibilities:

• Maintain required mill feed rate and grinding capacity.

• Monitor gypsum feed size and ensure proper grinding.

• Maintain required product fineness.

• Monitor mill vibration, differential pressure, motor load and other operating parameters.

• Ensure stable feeding to the calcination section.

• Avoid mill choking, overloading and empty running.

• Optimize mill operation to reduce specific power consumption.

• Coordinate with Maintenance for abnormalities and breakdowns.

3. Calcination Section

Responsible for operation and monitoring of:

• Vertical Calciner / Kettle

• Boiler / TFH

• Coal Feeding System

• ID Fan / Blower

• Rotary Valves

• Screw Conveyors

• Calcined Gypsum Silos

• Associated temperature, pressure and instrumentation systems

Key responsibilities:

• Maintain required calcination temperature and residence time.

• Ensure stable and continuous feeding of gypsum to the calciner.

• Monitor:

o Feed rate

o Calcination temperature

o Material temperature

o Coal consumption

o Airflow

o Draft/pressure

o Boiler/TFH parameters

o Product quality

• Ensure proper calcination and avoid under-calcination or over-calcination.

• Maintain required coal consumption per MT of stucco.

• Optimize fuel and air ratio for efficient operation.

• Monitor calcined gypsum quality and take corrective action whenever parameters deviate.

4. Process Control & Optimization

• Maintain process parameters within the defined operating range.

• Identify abnormal trends before they result in production loss or quality problems.

• Optimize mill capacity, calcination rate and fuel consumption.

• Monitor specific power consumption and coal consumption per MT.

• Identify opportunities for energy and process optimization.

• Maintain operating standards and SOPs.

5. Quality Control

• Ensure required gypsum/stucco quality as per specification.

• Coordinate with the Quality/Lab team for:

o Fineness

o Setting time

o Free moisture

o Combined water

o Bulk density

o Other applicable quality parameters

• Take immediate corrective action in case of quality deviation.

• Maintain traceability between raw material, process parameters and finished product.

6. Equipment & Process Reliability

• Carry out routine inspection of operating equipment.

• Identify abnormal sound, vibration, temperature, leakage, belt/chain condition, etc.

• Immediately inform Maintenance about equipment abnormalities.

• Coordinate with Maintenance during breakdowns and planned maintenance.

• Ensure equipment is handed over safely for maintenance and properly taken back after completion.

• Minimize production loss due to operational issues.

7. Coal Consumption Monitoring

• Monitor daily coal consumption and calculate kg coal/MT of stucco.

• Reconcile coal feeding with production.

• Identify abnormal/excessive coal consumption.

• Maintain daily coal consumption records.

• Work on initiatives for coal reduction and heat recovery.

• Support implementation of coal weighment and automated feeding systems.

8. Silo & Material Management

• Maintain optimum levels of:

o Raw gypsum silo

o Ground gypsum silo

o Calcined gypsum/stucco silo

• Avoid silo overflow and low-level situations.

• Coordinate grinding and calcination operation based on silo availability.

• Ensure proper material transfer and avoid unnecessary material handling losses.

9. Shift Management

• Supervise operators and helpers working in Grinding and Calcination.

• Allocate manpower effectively.

• Ensure proper shift handover.

• Maintain shift production and process reports.

• Ensure operators follow SOPs, checklists and operating instructions.

• Monitor operator discipline and performance.

10. Safety

• Ensure safe operation of Grinding and Calcination equipment.

• Ensure PPE compliance.

• Follow LOTO requirements during maintenance.

• Ensure safe handling of hot material, coal and rotating equipment.

• Report unsafe conditions immediately.

• Ensure compliance with plant safety procedures and emergency protocols.

Preferred Candidate:

Education - Diploma/ BE (Mechanical)

Experience - 4-6 years of relevant experience

Product knowledge- Gypsum / Cement

Behavioural Competencies - Ownership & Accountability, Learning Agility, Problem Solving &

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