FLO Instrumentation

Job Purpose
Plan Monitor and Coordinate the Instrumentation Maintenance Functions of Viscose Section PC1 and PC2 so as to ensure Optimum Production and delivery with target Cost and Quality.
Job Context & Major Challenges
Job Context
VSF-SFD, Nagda Plant has started in 1954 and in present scenario 100 % Automation in sections like Viscose, Spinning, Auxiliary and partial automation at CS2, Acid, ETP & RO. We have advance DCS systems of Yokogawa with latest digital technology as well all latest instrumentation systems in each section. We have approximate 800 VFDs for various machine at entire Plant.
Main Challenges with us are: 1. Maintain Automation and Packaged system (DCS) Instrumentation. 2. Competitors are more aggressive for Product quality and quantity. Thus there is need of consistence productivities and quality to satisfy customers need.

• Focus on Maintenance cost reduction and Energy conservation. 4. Focus on unplanned down time, reduction in inventory. 5. Betterment of Instrumentation & Automation system to ensure safety.
• Non availability of machines for maintenance due to continuous running of process.
• Highly Corrosive environment leading to high level of corrosion of electronic cards, resulting in higher failure rate.
• In Viscose Section Control system is combine for PC-1 (M/c- 1, 2, 3, 4, 5, 6, 7 & 10) so it is very difficult for PM during individual line stoppage.
• Dissolver Sequence Logic complexity to understand & resolve issue
• Auto pulp feeding system troubleshooting complexity.
• Maintenance of 40 KVA UPS for DCS System.
  

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)
KRA1 Upkeep
Monitor & coordinate maintenance activities of VSF plant so as to achieve optimum production loss & delivery within target cost & quality 1. Preventive Maintenance Execute & implementation

• Predictive Maintenance Check list execution & Evaluation
• To assist for Breakdown maintenance job Execution
• To Assist for RCA & Why-Why Analysis to avoid repeated problem & Implementation of action plan
• Field Instrument protection monitoring by plant round & corrective action accordingly
• Shutdown Activity execution within timeline
• Focus on Reduction in Unplanned Instrument Downtime
• Focus on Reduction in Unplanned Instrument Downtime
• Upkeep the Pulp handling system to meet manufacturing targets.
• Maintenance of PA system at Pulper Area.
• Upkeep of CS2 sensors.
• Upkeep & Maintenance of 40 KVA UPS (02 nos.)
  

KRA2 Control System Maintenance
To ensure continuous DCS support & trouble shooting 1. Assist to ensure the availability of control system to meet the manufacturing targets and other customer requirements.

• Health monitoring & corrective action to maintain uptime of Controller, I/O cards & operator work station.
• Ensure closed loop controlling by monitoring final control element function & tuning parameter setting.
• Sequence operation troubleshooting to run batch process smoothly.
• To assist for Control system Preventive Maintenance Schedule preparation & Evaluation.
• Ensure PLC system availability by maintain Grounding & power supply within limit.
  

KRA3 Modification/Improvement Projects : To suggest the modification / improvement projects to improve quality & productivity 1. To assist in product development and plant up gradation

• Execute technological change for improved Quality, GMP & Safety.
• Provide the services & equipment needed for new products and formulation changes
• Identify/Execution of KAIZEN for implementation
• To assist for small modification & 1. To assist in product development and plant up gradation
• Execute technological change for improved Quality, GMP & Safety.
• Provide the services & equipment needed for new products and formulation changes
• Identify/Execution of KAIZEN for implementation
• To assist for small modification & improvement project implementation
  

KRA4 Spare Management & Cost Optimization
Planning & Monitoring spares management to ensure better cost optimization. 1. To assist for Identifying and procuring the required equipment spares and accessories by proper planning

• Maintaining BOM for Instrument apparatus
• To assist for Procuring required materials by floating PR
• Instrument maintenance execute by utilizing in-house resources
• Resource management for day to day & shutdown activity
  

KRA5 People Development
To enhance knowledge & skills of team/subordinates. 1. Development of maintenance team by providing training to technician

• Train the workforce for safe practices & technical subject
• Appraise, Inspires & stimulate subordinate to maximize their performance towards department goals
• Developing team work culture
  

KRA6 Safety & Statutory Compliance
To plan the various safety initiates to create safe working condition & also meet the statutory compliances. 1. Critical Instrument Calibration as per Schedule & record maintain accordingly

• To assist for IMS, WCM, process safety documents to meet the respective standard requirements
• To assist for internal & external audit compliance
• HIRA , ASPECT-IMPACT procedure follow & action plan implementation
• Six step Safety Observation process follow-up as per schedule
• Betterment of Instrument System to Ensure Safety
• Ensure safety practices implementation within team.