Section Head QC

Job Purpose

To Coordinate with Mines & Raw material deptt for Lime Stone & raw material quality respectively. Entire quality control of Raw material, semi-finished & finished product with coordination with production team of 2.6 MT plant at optimum cost as per the set organization requirement, safety and quality guidelines.

Job Context & Major Challenges

Job Context

Bela Cement Works is located 220 km from Jabalpur and 18 Km for Rewa Madhya Pradesh, around 06 kms from National Highway No 7 & 30. It has a cement manufacturing capacity of 2.6 MTPA and clinker capacity of 2.1MTPA. Bela plant is 6700 TPD, 6 Stage 2 String, SLC pre-heater plant which is engineered, manufactured and supplied by M/s Larsen and Toubro Limited (FLS) and commissioned in the year of 1996. The original capacity of this plant was 4500 TPD, and in the year 2003 it was upgraded to 6700 TPD. The unit has cement grinding capacity as well as clinker export facility.Limestone requirement of the plant is 3.1 MTPA. To meet the limestone requirement, limestone mines are spread over 649 Ha having deposits sufficient for around 40 years. Limestone crusher with capacity of 900 TPH, located inside plant. Material is transported from mine to plant through Dumpers.The Unit has one captive thermal power plant of 25 MW in addition to 5 MVA Grid Power Connection with SEB to cater the entire power requirement of the unit. Plant has a private railway siding for its inbound/outbound material, fuel, cement and clinker movement. Water requirement of plant is catered from water harvesting pits in mines.

Job Challenges

• To coordinate, analyze & inform the quality of Limestone to Mines.
• To ensure shift Chemist to analyze & inform the test results to process for corrective action if required.
• Dealing with BIS for License & marking fee. Implementation of all statuary plans of BIS for regular testing of cement.

Key Result Areas

• Supporting Actions
• Accountability: Quality Control : To supervise, monitor and control quality of raw materials, process intermediates and finish products as
• per plan through proper sampling and testing

• Monitor daily samplings and sample preparation of incoming, in-process and finished products material such as Coal, Gypsum, Clinker and Cement.
• Check X-ray analyzer through standard samples.
• Maintain spare parts of test equipment.
• Preparation of raw mix design
• Monitor Coal ash, moisture analyzer and auto sampler.
• Monitor activity of quality management module of SAP & Data feeding.
• Monitor working of CBA on day-to-day basis and compare the results with XRF to assure the desired quality of limestone from mines.
• Ensuring sampling and testing of all the materials as per plan.

• Ensure the calibration of all the test equipments as per plan.
• Maintenance of Chemical Stores inventory.
• Assuring conformity of test results with the statutory requirements of BIS, DGS & D and internal specification.
• Implementation of NCB & C R&D findings in Shift,
• Physical & Chemical laboratories.
• Tracking the quality data in the shift lab operation.
• Finding the deviations in the test results against standards and informing to the related agencies.
• Ensuring the normalization of deviation in the shortest possible time.

Statutory compliance: Coordination & monitor maintenance of all statutory BIS standard requirements and also comply them

• Collection of data on daily basis.
• Coordinate activities during BIS official visits.
• Take corrective actions to fulfil the requirements.

• Product changeovers in grinding to be minimized to minimum 8 Hrs to ensure quality of product.
• Product changeovers as per the requirement of Marketing and cement mill / raw material availability.

• Arrange for sampling and testing of market cement samples as per TRC guidelines.
• Sampling and packing of samples and delivering to external agencies as per requirement.
• Attending to customer complaints and analyzing the cement samples collected from market.

SHE (Safety, Health & Environment) along with Sustainability initiatives

• Ensuring 100% compliance of all safety standards and all applicable recommendations related to section to ensure 0 LTIFR
• Build strong believe and adherence among 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, O&S, WB & CL manpower
• Ensure strict compliance of procedures in routine jobs and Adhering of all safety precautions on the site and off the site
• Timely conducting self and team scheduled SO round and reporting of accidents, incidents and near misses on occurrences in section head in system. Also conduct CFSA by self & team as per schedule to ensure contractor safety as per CSM guidelines
• To ensure daily Tool Box Talk and deliberating on safety incident or knowledge sharing
• Active participation in safety training, safety sub committees, standard champions meeting and any safety event by self and team
• Ensure that there is no waste of power in section, no leakage of water, oil, air etc and time to time auditing and rechecking such areas for timely action
• Ensure good health of self and team and creating awareness among team about sustainability initiatives of unit, business and group.

System Management:-

(Implementing & monitoring effective execution of IMS and other systems in QC for overall improvements towards productivity and creating safe work culture)

• To plan & execute timely ABOEF process activities in respective Section like 5S, BCE, hygiene, Model area, illumination, good maintenance practices, visual & Lubrication management, QCDIPSHE performance, Kaizen, OPL, improvement projects etc for internal customer satisfaction.
• Review procedure requirements & recommend amendments for continuous improvement.
• Actively taking lead in meetings for implementation good practices in improving associated KFA and GRT performance and carry out internal audits to ensure effective implementation of systems
• To inculcate team for reducing repetitive nature problem, training other on tacit knowledge, adapting new technology, bring kaizen & improvement projects, adherence & develop preservation SOPs.
• Provide Internal & External audit responses in time
• Ensure proper implementation of IMS standards by timely updation of documents & control, reviewing standards requirements, taking corrective & preventive action against findings internal and external audit/assessments finding for timely closure for 100% compliance.

Build & sustain a conductive work culture within section to enhance productivity of section through involving people for growth & motivating them for implementing new technology, innovation, creative things by way of replicating best and unique practices

• Setting of SMART and differentiating Goals Setting aligning with Unit and Business targets, time to time review performance and giving or seeking quality real time constructive feedback on performance appraisal and other areas. Recommending team for Rewards and recognition without any biasness to DH.
• Assigning multiskilling tasks for developing them for next role through The 70:20:10 Model for Learning and Development to develop functional and behavioural competencies.
• To ensuring that as per development needs team attends desired training and nominating them for other training and development initiatives
• Empowering team for taking independently action and appreciating them for taking risk and motivating them through employee wellness and wellbeing initiatives within department and having participative culture.
• Having regular communication that count with maintains transparency for top to down communication (mentoring, guiding, coaching, counselling etc.)
• Prepare action plan based on Team Vibes Results of direct reportee to enhance engagement level of team.
• Ensuring for maintaining discipline, handling and resolving grievances at individual level and building strong interpersonal skills
• Involving them in department or cross department projects leading for unit, Business or Group level performance