Flo Safety- Paints Manufacturing- Mahad

**Designation**:Executive

**Updated**:January 15, 2025

**Location**:Maharashtra, India

**Organization**:Paints HO

**Job Purpose**:
Design, plan, organise, co-ordinate, control and monitor quality of all incoming raw materials, Fuels, in-process and finished products through raw mix design,sampling, inspection and analysis at various phases of operations. Coordinate with Packing plant & CCR for timely giving clearance during grade changeover. Guide the plant in producing optimum quantity and consistent quality of products. To co-ordinate, organise and monitor Raw Material Handling within budget limit. Also organise and co ordinate research and development activities for innovation / new upgraded products, in plant to ensure 100% statutory compliance. To compare our cement with competitors for producing good quality cement.

**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. It is also one of the leading cement producers globally. The company has a consolidated capacity of 132.45 Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants, 1 Clinkerization plant, 27 grinding units and 7 bulk terminals, post the Century merger. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.
UltraTech, Rawan Cement plant started its Line 1 operation in early 90's with the capacity of 1 MTPA, commissioned in March, 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March'2013, Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility, currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW, Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch, Germany for grinding limestone and coal, Kiln and cooler from L&T/FLS, Denmark, Combi-Grinding Cement Mill with Roller Press from KHD, Germany, Finish Grinding Slag Grinding Roller Press from Krupp Polysius, Germany, Cross belt analyser from Gamma Metrics USA for on-line analysis of Limestone, X-Ray analyser, Cem Scanner from FLS, Denmark.
As the largest cement producer in India, we continually strive to play a key role in finding effective and responsible ways to preserve the environment - a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management, energy reduction, water conservation, biodiversity management, afforestation and emission reduction which are relevant to the cement industry.
Major challenges:
The captive limestone mines is of marginal grade with high alkali. Raw mix design to ensure productivity and desired quality is a critical task considering the limestone quality.
The higher alkali in clinker affects the progressive increase in strength at all ages with lower later age strength. To be ahead of competition, product quality with these limiting factors is a major challenge.Provide desired quality product to the customers as per the internal specification. Production planning for OTIF deliveries as per the production plan.Handling of raw materials inside the plant to ensure cost effective consistent running of production process (Iron Ore-0.2 Lac MT per annum; Coal-2.2 Lac MT per annum; Slag-3.5 Lac MT per annum; Fly ash-1.0 Lac MT per annum; Gypsum-0.7 Lac MT per annum)
To plan and operate packing facility at Raipur, which is 80 KMs away from plant (BIS licenses for the PSC and PPC are operative)
Analysis of all the samples from the coal washery to ensure cost effective washing and handling of coal.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1
- Accountability
- Quality Control
Organize inspection, sampling and testing of all the raw materials, in-process materials and finished products.
Co-ordinate and monitor the production of consistent quality of product.
- Testing frequency as per the Quality plan on daily basis.
Calibration of test equipment as per quality plan.
Monitor the lab results and guide for corrective actions in case of deviations.
- KRA10
- Niche market development and support to Marketing on capturing new / emerging markets
- To understand the requirement of niche / emerging market from TASC.
To develop product suiting to the new requirement.
To organize customer meets and visit key customers for product promotion / entrenchment in the market.
- KRA11
- Receipt and Acceptance of Wastes, Production and Delivery of Agreed Quality and Quantity of AFR and Compliance with Statutory Requirements
- '¢ Develop a receipt plan for wastes to match final AFR agreed specifications based on compatibility of wastes.
'¢ Obtain and maintain plant's license for TSDF (