PF Mechanical (Kiln & Cooler )

Job Purpose

Plan Organise & Co-Ordinate the implementation of Field Operation &maintenance activities in Kiln & Cooler for optimum plant availability within optimum cost to meet production target, Execution of improvement / modification jobs for cost reduction and productivity improvement along with manpower planning and spare parts management, system implementation for best practices by ensuring pollution free and safe working environment.

Job Context & Major Challenges

Job Challenges: 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 116.75 Million Tons Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 26 grinding units and 7 bulk terminals. Nathdawara Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Binani Cement Limited in the year 2018.

Nathdwara Cement Plant was commissioned with the manufacturing capacity of 4.8 MTPA and clinker capacity of 4.81 MTPA. The first unit was installed in 1997 and second unit was installed in 2007. Grinding Unit, Neem ka Thana was commissioned in 2007.

Limestone requirement of the plant is 4.5 MTPA. To meet the limestone requirement, limestone mines are spread over 724.7 Ha having deposits sufficient for around 50 years. Limestone crusher including wobblers having capacity of 1000 TPH, located inside the plant. Material is transported from mines to plant through dumpers.

The Unit has three captive thermal power plants of 24 MW & 2X23 MW i.e. a total of 70 MW. WHRS of 23 MW and Solar Plant is also there.

The Cement & Power Plant is located at strategic location on Highway Cement is more than requirement and 40% manpower is Land Sellers who got job in consideration of Land. The skill & competencies are very less. The attitude towards work and job is not very appreciating.

Job Challenges

100% Equipment availability for 365 days continuously. Maintain zero accident. 100% Implementation of systems like QMS,EMS,OHSAS,WCM and SAP, Controlling of maintenance expenditure well within norms. Coordinate the challenging of execution of maintenance related activities. Ensure pollution free environment to improve manpower efficiency and productivity.

Key Result Areas

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

Kra1 Plant Availability

Plan, Organise and monitor implimentatin of mechanical maintenance activities for optimum plant availability in pyro section as per target to meet production of kiln as per requirement and satisfactionof internal customers.

• Coordinate the challenging of implementation / execution of maintenance activities Execution of preventive & corrective maintenance activities.
• Ensure periodic checking.
• Manpower planning one day in advance for daiy jobs.
• Proper Job planning for shutdown jobs.
• Spare parts planning for manjor shutdown jobs as well as fulfilling day to day basic requirements.
• Analysis of major / minor breakdowns and plan corrective actions accordingly.
• 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.

Attending coordination meeting regularly for discussion of plant performance on day today basis, collecting related feedback from internal customers, communicating subordinates and assure for the execution of corrective actions

• KRA2 Identification , Planning, & implementation of small modifications for better equioment performance.
• Proper coordination woth other departmets.
• Training to the workmen through workers development programmes and onsite training programmes for skill upgradation.
• Plannig and procurement of advanced good quality tools and tackles for fast execution of jobs.
• Daily monitoring of equipment health and maintaining records.
• Maintaining proper housekeeping and following good maintenance practices.
• Discussion on chronic problems.

Kra3 Cost Control

Plan monitor and control spares and lubricants inventory and manpower cost as per budget in mech maintenance activities in coal mill in order to optimize the maintenance cost. Prepare Budget for KILN 1&2 area.

• Monitoring expenditure with resoect to budget.
• Classification of most critical and less critical and general spares.
• Accordingly spares procurement from OEM and Reputed substitutensuppliers.
• Carry out life value analysis for high value spares.
• Inspection of materials from reputed suppliers as per OEM requirement for achievinglonger life of equipment.
• Monitor stores inventory reduction , standardisatin and optimization
• Monitoring of contract cost comparing wth last year expenditure.
• Close monitoring on workers overtime.
• Planning odf spare parts and raising indent for procurement as per requirement.
• Identifcation of maintenance cost reduction parameters.

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.