PF Process (VAP)

Job Purpose

Supervise the production of New Products (Textura, Kool n Seal & other products) and testing of all raw materials, in process & finished product so as to achieve targeted production as per specified quality norms to fulfill market demands.

Job Context & Major Challenges

Job Context

Birla White is White Cement division of UltraTech Cement Limited and is a P&L centre. In India, BW is leader in White Cement as well as main Value Added Product Wall Care Putty with WC installed capacity of 680,000 MT per annum and Wall Care Putty capacity of 8,50,000 MT per annum. Business has plans to increase White Cement capacity by another 7, 20,000 MT and Wall Care Putty capacity by another 4, 50,000 MT per annum. Birla White plant is fully integrated and automated processing. The plant is accredited with ISO 9001, ISO 14001, ISO 50001, SA 8000, and OHSAS 18001. BW sells WC & WCP in multipack variants of 1 KG, 5KG, 20 KG, 25 KG, 40 KG and 50 KG.

In White Cement category, there is only one major competitor M/s JK White Cement with BW commanding a Market Share of 52.3% whereas in cement based putty, there are multiple competitors across organized and unorganized sector with BW commanding a market share of over 45.5%. Over the years, WCP has grown to become major contributor to White Cement Industry and is contributing 60%-65% of the total revenues. However with Paint majors (Asian, Berger, Nerolac etc.) becoming a potent force in WCP market, it is becoming extremely difficult to maintain the high margins the industry has achieved in the past.

Job Challenges

• To ensure the quality of all raw material required to produce ( Textura, Kool n Seal & other products )consistently as per prescribed norms. To ensure the quality of finished product
• Supervision is a challenge in view of the variety of raw materials and production being batch process, stringent quality control is necessary in order to achieve production of ( Textura, Kool n Seal & other products as per quality norms consistently.
  
  

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 Testing

Test all raw materials, in process & finished product in the production of new products so as to meet quality standards

• Ensure collection of samples as per timelines
• Test all raw material samples, in process & finished products as per specified quality standards & time bound plans on daily basis.
• Identify abnormalities or deviations if any
• Inform HOD (R&D) for corrective actions
• Implement corrective actions
• Keep, maintain & update all quality records.
• Test all samples received from market & report HOD (R&D)
  
  

KRA2 Production

Supervise the day to day operation of Production ne products so as to meet market demands

• Allocate the manpower as per production plan
• Take stock verification in the beginning of the shift and inform HOD ( R&D) & Logistics
• Closely supervise and monitor manpower engaged & material consumption
• Identify operational abnormalities and inform HOD ( R&D) for corrective actions
• Supervise packaging as per standards
• Prepare daily production report & submit to HOD (R&D) & MIS
• Keep update & maintain all production records
• Suggest continuous improvements in the process
  
  

KRA3 Material management

Coordinate for procurement of raw material, chemicals , packaging bags from stores & Purchase for ensuring smooth production.

• Identify material requirements for production and inform HOD (R&D)
• Plan material requirements as per the approved target
• Preparation of Indents for material requirements as per plan
• Checking of material as per the quality standards in stores
• Coordinate with stores for issue of material
• Control usage of material & inventory
• Deposit old material to stores after new issues
• Inspect proper usage of material & bags.
• Physical verification of raw material as & when required in coordination with Accounts, stores & civil.
  
  

KRA4 Safety Assurance

Ensure implementation of all safety provisions during execution of Production

• Ensure use of PPE
• Take work permit before carrying out any job in case required
• Implement all safety provisions as per SOPs.
• Daily Communicate all safety guidelines to all Workmen at production site before starting the work
• Keep constant vigilance for implementation of all safety procedures at site
• To conduct retailers meet and coordinate with CASC personnel for imparting training to retailers on new products & technical aspects of products
• To collaborate with CASC personnel in conducting painters meet.
• To conduct & completely handle counter meets & spreading awareness of BW applications & products to painters of a specific counter
• To conduct trade exhibitions & ensuring the proper presentation at stall & attending to customers at the stall to spread awareness of the products & applications
• To conduct cluster campaigns after carefully selecting clusters of customers & making the end user aware of the new products & applications
• To coordinate & provide support to CASC personnel for sampling to be done at micro level.
• Ensuring proper utilization of budget for promotional activities
  
  

KRA5 Quality Systems

Implement ISO, EMS, WCM , SA8000 & OHSAS related activities in the department

• Identify & get rectify.
• Abnormalities.
• Unsafe conditions/practices.
  
  

5S activities.

• Points emerged in campaigns..
• Execute implementation plan for
  
  

SA 8000/ OHSAS 18001 - implementation

Improvement of WCM criteria score.

EMS targets.

Internal customer rating improvement.

Statutory compliance.

• Elimination of muda.
• Does why why analysis.
• Prepare/present weekly/monthly WCM presentation.
• Develop one point lesson.
• Update WCM activity boards.
• Develop Model area.
• Develop visual controls.