Job Purpose
To support SH Mechanical in Planning, Organizing & Coordinating the implementation of Field Operation, preventive & predictive maintenance activities in Cement Mill for maximum plant availability within optimum cost to meet production target adhering with UTCL safety standards.
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
- Less availability of equipment's for maintenance due to continuous plant operations and high despatches.
- To ensure optimum availability of Cement mill throughout the year and systematic implementation of maintenance schedule to achieve production targets.
- 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
- Ensuring timely submission of Section Provisions like Budget, Flash Cost, Bills, PR, Service Entries etc.
- Review daily reports and maintains required records regarding operations as requested.
- 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.
