PF Mechanical (Packing Plant)

Aditya Birla Group

Harduaganj, India

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Job Description

Job Purpose

To support the Section Head - Mechanical in planning, organizing, and coordinating mechanical field operations and maintenance of the Packing Plant systems, including packers, roto packers, spout assemblies, aeration systems, bag filters, bag applicators, palletizers (if applicable), truck/wagon loading machines, conveyors, elevators, air slides, compressors, and all associated auxiliaries.

The role involves implementing and monitoring preventive, predictive, and conditionbased maintenance practices-such as vibration analysis, thermography, lubrication management, and visual inspections-to enhance equipment reliability, improve MTBF, and ensure consistent packing and dispatch operations.

The position holder is responsible for planning and executing planned shutdowns, packer overhauls, major maintenance activities, and breakdown interventions to minimize downtime, avoid packing losses, and ensure maximum plant and dispatch availability.

Further, the role focuses on optimization of maintenance costs through effective spare parts planning, structured job execution, inventory management, and RCFAbased corrective and preventive actions for repetitive failures.

Strict adherence to UltraTech Cement safety standards, statutory requirements, and maintenance SOPs is mandatory, along with close coordination with operations, electrical & automation teams, dispatch, OEMs, and contractors to achieve packing and despatch targets, product integrity, and Zero Harm objectives as per PF and WCM guidelines.

Job Context & Major Challenges

Job Context:- Aligarh Cement Harduaganj (A unit of UltraTech Cement Limited) is located at Village Kasimpur , Tehsil koil Dt. Aligarh (U. P.). It is a grinding & packing unit with an installed capacity of 4.5 MTPA. This unit was commissioned in May -09 consisting of Close Circuit Ball Mill with High Efficiency Separator, 2X12 spout Packer Machine. It manufactures Ultratech Cement in various Blends. This unit is one of our most modern establishments of UltraTech cement Limited. The basic raw material i.e. clinker received from Vikram Cement, Khor (M.P.) and Aditya Cement, Shambhupura (Rajasthan).
The main product is flyash based, which is being sourced from Thermal power station Aligarh and cement is supplied to mainly in Eastern UP .. The plant has a state of the art technology featuring Expert System of DCS with fully equipped modern laboratory to ensure optimum production and consistent quality product, these are the latest equipment in cement grinding process. 1. To reduce the power consumption. 2. To increase the flyash TPH to design capacity
Major Challenges -
1.Less availability of equipment's for maintenance due to continuous plant operations and high despatches.
2.To ensure optimum availability of Cement mill throughout the year and systematic implementation of maintenance schedule to achieve production targets.
3.To optimise operations to achieve better business results in power consumption, fuel consumption and fly ash consumptions.

Key Result Areas

	KRA (Accountabilities) (Max 1325 Characters)	Supporting Actions (Max 1325 Characters)
KRA1	Plant Availability: Plan, Organize and monitor implementation activities for optimum plant availability	- Execution of preventive & corrective maintenance activities. - Ensure periodic checking. - Manpower planning one day in advance for daily jobs. - Proper Job planning for shutdown jobs. - Spare parts planning for major shutdown jobs as well as fulfilling day to day basic requirements. -Interaction with OEM and suppliers for elimination of critical equipment problems. - Execution of all the major jobs during shutdowns. - Planning of contractor jobs to be carried out and raise service work order accordingly. - Proper coordination with other departments. - Daily monitoring of equipment health and maintaining records.
KRA2	Cost control:	. Reduction in section cost by reducing breakdowns. . Reduction in section cost by avoiding idle running of equipment. . Avoid over time and optimum utilization of contract manpower . Control the handling cost by avoiding Spillage.
KRA3	Management Information System	1.Ensuring timely submission of monthly MIS / Presentations and Reports 2.Ensuring timely submission of Section Provisions like Budget, Flash Cost, Bills, PR, Service Entries etc. 3.Review daily reports and maintains required records regarding operations as requested. 4.Ensuring periodic inspection and checking of all lifting tools and tackles.
KRA4	Focus on SHE (Safety, Health & Environment) along with Sustainability initiatives	Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area. 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 Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP Active participation in safety training, safety sub committees, standard champions meeting and any safety event Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action Adhering of all safety precautions on the site and off the site Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.
KRA5	System Management (Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)	-To implement improvement project to reduce repetitive problems/breakdown or losses. -Timely submission of Kaizen, OPL, Good to fine, suggestion on system -Developing and sustaining Model area in respective sections -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 -To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments. -Implementation of critical spares & consumable SOP without any defilement - Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.