Pf Process

Job Purpose To support SH Process Pre Clinkerisation for Planning organising and coordinating departmental budget preparation of Production and SNS RPM implementation of ISO standard Ensure availability of critical equipment s by timely maintenance procurement of shut down related materials Job Context Major Challenges Job Context 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 Grasim Industries Limited GIL acquired Dharani Cements Ltd DCL a 200 TPD capacity mini cement plant located in southern part of Tamil Nadu with vast mineral resources of lime stone deposits available nearby in the year 1998 to strengthen it s position in lucrative Cement market of Tamilnadu Kerala Soon after acquisition GIL started setting up of a Greenfield one million ton capacity cement plant as a separate division of GIL known as -Cement Division - South- which was commissioned in April 2000 with state of art technology Robo Auto Lab first of it s kind in India DCL was merged with GIL in Nov 2000 to utilise mineral resources as well as manpower other resources optimally for both the Plants in line with consolidation taking place in Indian Cement Business The new plant has advantage of lower power fuel consumption operations have stabilised in the least time The Unit has to it s credit obtaining ISO 9001-2000 Certification in July 2001 EMS 14001-1996 Certification in October 2001 i e within one half year of start of operations GIL South is a state of art plant with latest technology featuring an assemblaze of fuzzy logic X-Ray analyser and CEM SCANNER operating with least a man power producing a range of premium brand of cement The technical know- how and main equipments were obtained from Fuller Losche KHD Job Holder is responsible for proper preparation of overall Departmental budget of Production SNS RPM along with ensuring implementation of ISO standards requirement and time tinme to ensure availability of critical equipment s by timely maintenance procurement of shut down related materials Job Challenges 1 Operate maintain process parameters as per Total Quality Integrated Management System for Kiln and coal mill as to ensure uninterrupted plant production 2 Carry out shutdown activies within budgeted SNS RPM 3 Material availability and consumption planning during shutdown Key Result Areas KRA Accountabilities Max 1325 Characters Supporting Actions Max 1325 Characters KRA1 1 Operational Management Operation and optimization of Kiln raw mill coal mill as to achieve the targeted production and Power o Production and SNS RPM Bugdet planning Process Studies to implement good practices Check out the critical requirements to ensure sustained run and work together with cross functional departments Flash Production planning Fuel consumption planning Maintaining CCR counter record and checking of production report Implementation and preparing of ISO docuements Maintain manpower schedule in KRONOS Putting production and SNS RPM budget in TM1 Clinker and coal rate loss booking Generate process Order of material Preparing PAT data Cross Checking of Production and consumption of material Automise and track kiln rawmill coalmill circuit to avoid idle running of equipment Calibration of lime stone china clay silica send laterite and kiln feed feeders KRA2 2 Plant availability Avoid trippings Planning and execute Shutdown activity Kiln o Attend and analyse stoppages and rectify the same to improve equipment availability or reduce start stop Ensuring critical tools and tackles timley maintenance and availability Be ready for opportunity maintenance Prepare work check list ensure availability of critical tools and with coordination of service department make shutdown bar chart for smooth work environment Prepare work check list ensure availability of critical tools and with coordination of service department make shutdown bar chart for smooth work environment Ensure full empty out of coal bin kiln and cooler before stopping the plant for shutdown and ensure 100 safe work condition like equipment cool down removal of hot material and preheater kiln coatings before carry out any specific job KRA3 2 Plant availability Avoid trippings Planning and execute Shutdown activity Kiln o Ensuring kiln inlet and riser cleaning in all shifts as well as checking physical condition of cooler HRB Maintaining daily record of fuel quality raw mix quality and shell radiation temperatures if any abnormality found inform to SH HOD as well as technical cell to take immediate control measures Red Box filling kiln inlet poking tracking kiln shell temperature monitoring raw mix and fuel quality parameters and managing shift manpower Daily Trends review and checklist execution Record day wise production and Power Consumption and prepare comparative data for study analysis KRA4 3 Process Maintenance Jobs Pyro Implementation of various process maintenance jobs in coordination with other maintenance department to improve equipment availability o Material planning for shutdown Physical inspection of received material in store Ensuring Sufficient manpower availability for shut down by conducting all gate pass process Physical Inspection castable and refractory condition Ensuring sufficient material shifting from store to site All process equipment maintenance and calibiration Raising PR for refractory castable general items spare parts for brokk UT pump mixer machine belt conveyor and brick lining machine Supply Bill posting in SAP VRM Coal Mill internal inspection separator inspection water flow check any material accumulation hot gas chamber damper calibration roller position calibration Ensure false air point to be arrested during shut down If found any abnormality inform concer department for corrective actions KRA5 4 Cost Control Optimized run of Kiln and coal mill o Achieve targeted power consumption and throughput of kiln and coal mill Refractory management Timely completion of kiln shut down activity Reduction in Stores spares cost Ensure proper hous keeping by zero spillage points to reduce RPM Monitoring of power consumption and specific heat consumption and take corrective action to reduce the same KRA6 5 SHE Safety Health Environment along with Sustainability initiatives o 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 KRA7 6 System Management Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition quality standards o 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 programmes 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