Flo-viscose

3 weeks ago

Gujarat, India Aditya Birla Group Full time

**Designation**:Engineer

**Updated**:August 31, 2023

**Location**:Gujarat, India

**Organization**:Pulp and Fibre

**Job Context**:
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 equipment's. The designated capacity was 63875 TPA. Post-expansion, this will now be scaled up to 133955 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 40 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**:
1. To work with and upkeep old machines in good working condition amidst hazardous & corrosive chemicals while maintaining all process parameters and safety standards.

2. To extract output from unskilled/ less skilled workforce through continuous training and motivation.

3. To maintain a balance between raw material, utilities and labour cost with market price of Viscose Staple Fibre to maximize margins.

4. To take the productivity and rationalization route for cost reduction and adopt WCM culture among relatively less educated workers.

5. To meet ever changing customer requirements and upgrade quality and range of product offerings.

6. To create and maintain safe work environment in the plant.

7. To constantly take initiatives for technological up gradation with minimum resource usage.

8. To improve worker's morale and moderate their behavior to increase their work commitment so as to reduce the absenteeism and maintain high performance culture and improved labour relations.

**Key Result Areas**:
**(A) **Production & Operations-To supervise and execute smooth Viscose production and operations so as to ensure production of Viscose in targeted quantity and desired quality within budget.**

1. To ensure Smooth plant operation by proper process management.

To maintain and timely control of the desired process parameters so as to maintain the desired quality and quantity of the viscose.

3. To coordinate with the service providers as Electrical, Instrument and Mechanical maintenance for the upkeep of the equipment's and smooth operation.

4. To coordinate with the Internal customer (Spinning Dept) from time to time for the feed backs on the Quantity and Quality of product supplied and proactive information sharing on the abnormalities which may affect the final production.

5. To take feedback on the Two hourly production planning to ensure timely action in Viscose process as per the Production rate.

**(B) **Production Quality and Cost Optimization
- **To execute and implement cost reduction and quality improvement measures in shifts so as to eliminate wastage and increase profitability.**

1. To execute and implement timely mitigation actions for arresting the leakages, spillages and overflow in the shift.

2. Identifying and prioritizing the running maintenance so as to ensure un interrupted supply of the intermediate products at various stages of the Viscose process in the shift.

3. To guide the workmen for reducing losses and implementing new ideas and automation.

4. Regular interaction with workmen.

**(C) **CAPEX and Project implementation
- **'To identify and execute new operations/innovations/projects for increased plant performance as per timeline**

1. To identify the new operations/Innovations for the increased plant performance.

2. Coordinating with the respective counter parts in the sister units for knowledge sharing and up gradation.

3. To ensure the timely sampling/ execution of the trials undertaken.

4. To implement and execute approved projects/ innovations as per timelines.

5. To prepare budget of normal and major maintenance.

6. To implement capex of the respective section.

**(D) **Safety and Environment
- **To execute and implement safety systems and procedures so as to ensure the target of "zero accident" and ensuring long term sustainability in the department**
- 1. To implement and execute safety syst

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