Sh - Spinning (Process)

1 week ago

Ahmedabad, Gujarat, India Aditya Birla Group Full time

Designation:
Deputy Manager

Updated:
June 03, 2024

Location:
Gujarat, India

Organization:
Pulp and Fibre

Job Purpose:

Producing and delivering of the desired Quantity & Quality of Fiber by effectively utilizing the available resources at optimal cost

Job Context & Major Challenges:


Birla Cellulosic is the latest unit in Group's Pulp & Fibre Business established in 1998 with latest state of the art technology comprising of DCS control and certain imported equipments.

The designated capacity was 63875 TPA. Post-expansion, this will now be scaled upto TPA.

Consequently, it is expected to produce best quality of VSF in the group with consistency and at lowest cost of production and establish benchmarks with the group.

The Unit meets the requirement of fibre in both domestic and export market.

Post-expansion, a 25 MW extraction mode captive power plant having interdependency with VSF operation is integrated with zero tripping tolerance.

There has been continuous improvement on all fronts viz quality, safety, production, productivity, product grades, consumption ratios, environmental aspects etc.

These are to be sustained and improved further for providing a competitive edge to the business. Viscose preparation is a chemical process and it involves a sequence of operations.

Few important unit operations are:
Alkylation, Xanthation, Filtration, de-polymerization, de-aeration, Refrigeration & use of catalyst etc.

Control of various parameters in each operation in narrow band is required to maintain standard quality of the final product.

It is also required to update the old technology to improve quality product, reduce cost of production, energy conservation & maintain safe work environment etc.

Major Challenges

Position Challenges:
Water consumption in the process is high which would pose challenge during bad monsoon
Carrying out rehabilitation, repair and technological innovations in running plant - sustaining production and quality without sacrificing safety and environment
Resistance by the Collective bargaining units about bringing technological changes

Unit specific Challenges:
Machine 1 & 2 were developed in house, it's very old technology - which limits productivity, quality and cost optimization
Machine 1 & 2 doesn't have Digital Control System (DCS) which impacts manpower cost and process controls.
Line workmen technical competency is not at the desired level due to their current qualification
Quality of fiber produced in line 3 is superior compared to 1 & 2 hence effective bargain with customer to accept product from line 1& 2 is a challenge
Producing benchmark quality fiber by using in house pulp is a challenge
High energy consumption in the process due to usage of old technology
Maximizing CS2 recovery from the current level is a challenge due old technology
Reduction of Fugitive emission in the work environment which poses health hazard
Maintaining of consistent quality with the existing input raw materials

Key Result Areas:

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

  • KRA1
  • Production Planning & Control 1) Plan work flow and schedules for production departments.
  • 2) Monitor production status and ensure timely delivery.
  • 3) Identify delays and accordingly adjust schedules to meet deadlines.
  • 4) Assist in production risk assessment and mitigation activities.
  • 5) Provide excellent customer service and ensure customer satisfaction.
  • 6) Evaluate current production processes and recommend improvements.
  • 7) Assist in new product development and enhancements. KRA10 People Management Ensure employees are aware of their roles and responsibilities and deliverables
  • Create an enabling environment to discuss and share people issues at workplace
  • Identify and facilitate appropriate training of competency gaps with the help of HR department
  • Encourage and model the recognition culture at workplace
  • Ensure Safety and Environment awareness among employees and training wherever required
  • Develop line managers into people managers to handle day to day grievances with utmost sensitivity
  • KRA2
  • Production Planning & Control 8) Conduct daily meetings to keep track of production schedules.
  • 9) Ensure that finished products meet quality standards and customer specifications.
  • 10) Determine equipment, materials and manpower required to complete production.
  • 11) Resolve production issues and escalate unresolved issues to management promptly.
  • 12) Assist in employee hiring, training, performance evaluation, retention and termination activities.
  • 13) Ensure spares and raw material Inventory are available as per the desired stock levels to ensure no disruption in production activities
  • 14) Monitor and analyse Downtime with Root cause to reduce its impact on Cost, Quality and Delivery KRA3 Regulatory compliance 1) Ensure all the relevant regulatory compliances applicable to the operations are adhered to
  • 2) Participa

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