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Aditya Birla Group

PF Instrument - L2

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Job Description

Job Description

Job Purpose

To support the Section Head - E&I in ensuring maximum plant availability and improved productivity at optimum cost by supervising and coordinating the safe operation, maintenance, and reliability of instrumentation systems, automation software, and associated equipment. The role focuses on identifying and eliminating operational issues through effective instrumentation maintenance, process automation, and control system optimization, including requirement gathering, implementation of automation solutions, and continuous improvement initiatives, while strictly adhering to safety standards, statutory requirements, and business objectives

Job Context

Aligarh Cement Works - Harduaganj, a unit of UltraTech Cement Limited (Aditya Birla Group), is located at Village Kasimpur, Tehsil Koil, District Aligarh (Uttar Pradesh). The unit is a cement grinding and packing plant with an installed capacity of 4.5 MTPA, commissioned in May 2009.

The plant is equipped with modern cement grinding technology, including closecircuit Ball Mills with HighEfficiency Separators and 2 × 12spout Rotary Packing Machines, enabling efficient and reliable production of UltraTech Cement across various blended grades. The primary raw material, clinker, is sourced from Vikram Cement, Khor (Madhya Pradesh) and Aditya Cement, Shambhupura (Rajasthan).

A significant portion of production consists of fly ashbased cement, with fly ash sourced from the Aligarh Thermal Power Station, Kasimpur. Finished cement is predominantly supplied to Eastern Uttar Pradesh markets.

The plant operates with a stateoftheart DCSbased Expert Control System, integrated with advanced instrumentation and a fully equipped modern laboratory, ensuring optimized operations, reduced energy consumption, environmental compliance, and consistent product quality. The unit is recognized as one of the most efficient, technologically advanced, and highperforming units within the UltraTech Cement business.

Within this environment, the PF Instrumentation role is critical in ensuring reliable operation, availability, and accuracy of instrumentation, automation systems, and process data across grinding, packing, utilities, and environmental monitoring systems. The role also focuses on providing timely, accurate, and actionable data to management to support strategic and operational decisionmaking, while ensuring full compliance with statutory and regulatory norms.

Major Challenges

  1. 24×7 Environmental Data Availability
    Ensuring continuous, accurate, and realtime availability of environmental monitoring data (Emissions, Ambient Air Quality, etc.) to CPCB/SPCB portals, with zero data gaps or noncompliance.
  2. DCS and Process Data Accessibility
    Ensuring uninterrupted availability of DCS, PLC, and field instrumentation data to maximum users through PI systems / reporting platforms for effective process optimization, analysis, and report generation.
  3. Manpower Optimization and Skill Development
    Managing all Instrumentation and E&I activities with optimized manpower, while building multiskill capabilities within the team to handle both operational and maintenance responsibilities for smooth and reliable plant operation.
  4. Maintenance under High Operational Load
    Limited availability of plant and instruments for maintenance due to high dispatch volumes and fluctuating production demands, impacting equipment health and longterm reliability.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

KRA1

Plant Availability
Timely Completion & implementation
of maintenance activities for
maximum availability Instrumentation section for achieving
targets with respect to downtime,
maintenance work and customer
satisfaction.

1. Troubleshooting of Inst. Related problems in time for achieving the plant availability.
3. Follow maintenance plans.
4. Timely Completion of PM schedule.
5. Timely Completion of jobs in shutdown.
6. Review breakdowns & carryout analysis for problems.
7. Take corrective actions.
8. Installation, testing and calibration of all field instrument
9. Installation, commissioning, testing and calibration of weighing systems
10. Erection of IO panels, Optical fiber and Profi bus cable laying
11. Carryout why-why analysis, review drawings / specifications.
12. Analyses the frequent problems, tripping, breakdowns.
13. Identify areas requiring improvements.
14. Taking plant round, supervise maintenance jobs, coordinate with other dept. / Sections for plant performance improvement job.

KRA2

Cost Optimization

1. Prepare budget for E&I related activities i.e. maintenance, shutdown and project for consolidation into sections yearly Work Program and Budget.
2. Monitor budget utilization closely and provide justification for variance.
3. Plan, monitor and control cost (spares, Inventory) of Instrumentation maintenance activities P to optimize maintenance cost within the budget.
4. Inventory Review & Maintain Critical Spares
5. Reduce consumption by improving uptime of plant.
6. Controlling Overtime

KRA3

Data Security and Process Optimization.

1. Data security and configuration backups of all servers so that IT security compliance of our group are not violated.
2. Software upgradation and antivirus updates of all Servers, clients, engineering stations and firewalls.
3. Optimization of software loops for cost reduction and easy process operation.
4. Availability of plant data to maximum users through PI for easy process utilization.

KRA4

Continuous Improvement:
Study and identify projects,
coordinate and monitor
implementation of up-gradation/
modification/de-bottle necking/
improvement projects to improve the availability & reduce cost of Electrical & Instrumentation maintenance.

1. Collection of data on failures and bottlenecks & identification of improvements projects.
2. Analysis of failures.
3. Identify improvement actions.
4. Formulate proposal i.e., equipment specification, drawings etc.

KRA5

Shutdown Jobs Performing

Shutdown Jobs Performing
1. Prepare the job list for shutdown as per priority for the plant.
2. Proper Job planning for shutdown jobs.
3. Planning of contractor jobs to be carried out and raise service work order accordingly.
4. Spare parts planning for major shutdown jobs as well as fulfilling day today basis requirements.
5. Planning and procurement of advanced good quality tools and tackles for fast execution of jobs

KRA6

Management Information System

1. Ensuring timely submission of monthly MIS
2. Ensuring timely submission of Section Provisions like Flash Cost, Bills, PR etc.
3. Timely and accurate preparation of Presentations, Reports etc. as required by Management from time to time
4. Supporting and handling various internal and external audits.

KRA7

System Management
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)

1. To implement improvement project to reduce repetitive problems/breakdown or losses.
2. Timely submission of Kaizen, OPL, Good to fine, suggestion on system
3. Developing and sustaining Model area in respective sections
4. 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programs down the level team
5. To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
6. Implementation of critical spares & consumable SOP without any defilement
7. Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.

KRA8

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

1. Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.
2. Educating team about I know my job, I know the hazards associated with my job and I applied control measures & I escalate to my senior among manpower deployed in sections/department manpower including peer, WB & CL manpower
3. Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
4. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
5. Active participation in safety training, safety sub committees, standard champions meeting and any safety event
6. Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
7. Adhering of all safety precautions on the site and off the site
8. Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

Diploma

More Info

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Job ID: 148307125