Flo Viscose

**Designation**:Assistant Manager

**Updated**:January 08, 2025

**Location**:Gujarat, India

**Organization**:Pulp and Fibre

**Job Purpose**:
To plan shift maintenance activities and to monitor the same so as to ensure 100% machine availability and optimum production and delivery within targeted cost and quality parameters, maintaining the safety standards and also carryout developmental projects to improve overall working of the section with respect to quality, cost, systems & productivity.

**Job Context & Major Challenges**:
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 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:
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 behaviour to increase their work commitment so as to reduce the absenteeism and maintain high performance culture and improved labour relations.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1
- Plant Maintenance and Uptime
To plan, execute and implement systems and processes to ensure maximum availability of equipment of respective sections within budgeted cost and targets
- 1. To plan and execute preventive maintenance, major maintenance, general maintenance & lead maintenance for respective sections.
2. To plan and take initiatives to increase MTBF and implement and execute systems so that the breakdowns are attended with minimum MTTR.
3. To analyze problems and find appropriate solutions in consent with SH and take corrective actions accordingly.
4. To coordinate with purchase for availability of spare parts.
5. Review of the inventory w.r.t. to specific section on daily basis to keep it within stipulated limits.
6. To maintain the records of respective sections
7. Co-ordinates with user Dept.
8. Prepare MIS report of respective section.
- KRA2
- Maintenance cost Implement and execute maintenance cost reduction initiatives so as to reduce expenses to increase the overall profitability
- 1. Monitoring of plant & machinery health of respective sections thereby increasing the reliability of equipment and reducing the cost of operations.
2. To implement steps to improve the life cycle cost of respective section.
3. To suggest import substitute / new vendors for uninterrupted availability of parts.
4. To keep a check on maintenance cost on daily basis.
- KRA3
- Improvement projects To identify and execute new operations/innovations/projects for increased plant performance as per timeline
- 1. To identify, execute and implement the new operations/Innovations for the increased plant performance.
2. To ensure the timely sampling/ execution of the trials undertaken.
3. To implement and execute approved projects/ innovations as per timelines.
- KRA4
- CAPEX
'Implement capex for improving existing technology and operations in maintenance