Dh Process

**Designation**:General Manager

**Updated**:November 06, 2024

**Location**:Gujarat, India

**Organization**:Cement

**Job Purpose**:
To achieve budgeted production of Clinker,Raw Meal,Fine coal & Cement within budgeted specific power & fuel consumption and fixed cost. Also, ensure safe and smooth operation of Plant & Machinery.

To sustain ISO and WCM activities.

**Job Context & Major Challenges**:
To produce raw meal, clinker, fine coal & cement as per budget. Operating plant keeping low inventory of in process material with variety of low cost additives and with lower LSF of lime stone.

To adjust all operating parameters in order to produce quality clinker and cement within the norms by the given recipe. Major Challenges:
High volumetric loading of kiln (>7 TPD/m3)

High thermal loading of kiln (>6 giga calorie/hr/m2)

To achieve 345 days kiln running

To achieve budgeted clinker & cement production in such extreme conditions as mentioned above

**Key Result Areas**:
**KRA (Accountabilities) (Max 1325 Characters)**

**Supporting Actions (Max 1325 Characters)**
- KRA1- Accountability: Process Management:
Organize & coordinate production as per dispatch schedule and ensure optimum production and plant availability from process side by controlling process parameters/ process stoppages to meet targets and customer satisfaction.- Daily monitoring of production, monitoring process parameters optimization of process -Continuous interaction with other department for achieving plant run factor- KRA2- Cost Optimization:
To achieve less Sp power and fuel consumption- Monitoring section wise power on daily basis and take corrective actions

Ensure no idle running of equipment.

Ensure no false air infiltration in pyro and raw mill section

To interact with other departments for brain storming and further optimize- KRA3- Quality Consistency:
Monitor & review production of clinker of consistent quality to maintain brand image and improve customer satisfaction.- Monitor the test results.

Analyze the reasons for deviation.

Take correction action.

Review of quality of products.

Make changes in ISO standards form continuous improvement.

Check process capability to meet new standards.

Take action to improve process capabilities.

Ensure testing & calibration of instruments for accuracy.- KRA4- Co processing of AFR and *Refractory management- Set targets for thermal substitution rate and quantity of AFR in consultation with all concerned

Achieve the targets with mínimal impact on production and quality

Maximise AFR quantity and ensure availability of AFR feeding system
- Looking alternate of lower cost quality refractory material without compromising run factor to reduce Fixed cost and by adopting best practices of refractory laying
- KRA5- Process People Development:
Organise and ensure skill & competency development of people for working improvement in process control area.- Identify training needs

Recommend for training

Assignment tasks for job enrichment

Guide job rotation

Take training classes.- KRA6- Plan Process Improvement / Upgradation& *Shut down management:
Plan & implement plant process improvements / upgradations projects/ process parameters for new product, Environment, Safety, Productivity, Process Control & Quality.- Identify bottlenecks / Projects for improvements.

Analyse problems

Interact with OEM

Formulate proposal & seek approval

Check process capability.

Guide process optimisation.

Ensure implementation of plan

Monitor progress

Guide corrective actions
- Planning & Budgeting of refractories & other consumables at starting of year and timely completion as per Bar Chart with proper co ordination of Mech, electrical &other departments and completion of job with ensuring safety and quality.

**Qualifications**:
Bachelor of Chem Engineering

**Minimum Experience Level**:
10-18 Years

**Report to**:
Manager