PF Mechanical (PP Maint)

Aditya Birla Group

India

Fresher

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Posted 2 days ago
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Job Description

Job Purpose

To support SH Mechanical(Packing Plant) by planning, organizing and coordinating maintenance activities (Preventive/Predictive), manpower planning, spare parts management and execution of improvement / modification jobs in Packing plant for ensuring maximum plant availability and bringing cost optimization through productivity improvement to meet budgeted production targets.

Job Context & Major Challenges

Job Context: UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The company has consolidated capacity of 138.39 Million Tons Per Annum (MTPA). of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 29 grinding units and 8 bulk terminals.

Baga Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Jaiprakash Associated Limited in the year 2017. Baga Cement Works is located at around 155 Km from Chandigarh, 67 km from Shimla and 37 km from Bilaspur (HP). The nearest National Highway is NH-88 which is 17 Km from the plant. The plant has 10,000 TPD clinker production capacity & 250/300 TPH OPC/PPC cement grinding capacity. The preheater consists of four strings, each with 6 stages of LP cyclones, with two pyroclones supplied by M/s KHD. This is a unique feature of this cement plant due to which the plant operates at lower heat and electrical energy. The preheater has a height of 155 mtrs, with top floor at 135 mtrs. The preheater has been constructed out of tubular steel structure.

The Cement Plant is based on lime stone deposits in Baga - Bhalag hills which are adjacent to plant area. Limestone requirement of the plant is around 15000 TPD. For raw material grinding, two vertical roller mills of 420 TPH each have been installed with a C.F. Silo having a capacity of 24,000 MT.
The unit is equipped with state-of-the-art pollution control systems, and operating emission norms are much lower than the permissible standards of 30 mg/Nm3. Two continuous ambient air quality monitoring stations have been installed which are hooked up to CPCB and PCB and transmit real time data's.
For emergency electrical power, 8 x 1800 KVA, DG sets have been installed.
.The township for the plant is located near the plant and has a residential complex for 300 families. 10+2 school and 30 bed hospital has been built. For transporting clinker and cement from plant a fleet of about 4000 trucks have been engaged.

Key Result Areas

	KRA (Accountabilities) (Max 1325 Characters)	Supporting Actions (Max 1325 Characters)
KRA1	Accountability- Plant availability: Supervise & coordinate all the Mechanical activities of packing plant to maximize the plant availability to achieve continuous production as per targets	. Take plant rounds /study check list daily and identify problems. . Scheduling of weekly major shutdowns and regular maintenance activities. . Supervise of maintenance activities. . Analyze breakdowns . Take corrective and preventive actions. . Organize manpower & material required. . Prepare indent & follow-up for material. . Coordinate for condition monitoring activities of critical equipment's. . Coordinate with other departments for jobs. . Updating of daily & weekly checklist.
KRA2	Cost Control: Control cost of all the maintenance activities of packing plant as per budget in order to optimize maintenance costs	Prepare budget based on past data and future targets. . Check consumption pattern equipment-wise with respect to budget. . Take corrective actions. . Carryout Why-Why analysis. . Arrange manpower requirement in coordination with other section to control overtime & contractor cost. . Monitor the indents / inventory .Mechanize / improve handling system of materials. .Propose changes / modification for attending leakages.
KRA3	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.
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	Modifications/upgradation: Identify and carryout various -modifications/changes required for improvement in plant working on continuous basis in the section.	. Analyze breakdowns and suggestions. . Involve in for elimination of bottlenecks. . Involve in focused improvement jobs. . Attend improvement meetings.