Pf Mechanical

**Designation**:Assistant Manager

**Updated**:December 17, 2024

**Location**:Rajasthan, India

**Organization**:Cement

**Job Purpose**:
Plan Organize & Co-Ordinate the implementation of maintenance activities (Preventive/Predictive) in Coal Mill for optimum plant availability within optimum cost to meet production target, Execution of improvement / modification jobs for cost reduction and productivity improvement along with manpower planning and spare parts management, system implementation for best practices by ensuring pollution free and safe working environment.

**Job Context & Major Challenges**:
Job Challenges: 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. Nathdawara Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Binani Cement Limited in the year 2018.

Nathdwara Cement Plant was commissioned with the manufacturing capacity of 4.8 MTPA and clinker capacity of 4.81 MTPA. The first unit was installed in 1997 and second unit was installed in 2007. Grinding Unit, Neem ka Thana was commissioned in 2007.
Limestone requirement of the plant is 4.5 MTPA. To meet the limestone requirement, limestone mines are spread over 724.7 Ha having deposits sufficient for around 50 years. Limestone crusher including wobblers having capacity of 1000 TPH, located inside the plant. Material is transported from mines to plant through dumpers.

The Unit has three captive thermal power plants of 24 MW & 2X23 MW i.e. a total of 70 MW. WHRS of 23 MW and Solar Plant is also there.

The Cement & Power Plant is located at strategic location on Highway Cement is more than requirement and 40% manpower is Land Sellers who got job in consideration of Land. The skill & competencies are very less. The attitude towards work and job is not very appreciating.

Job Challenges:
100% Equipment availability for 365 days continuously. Maintain zero accident.
100% Implementation of systems like QMS,EMS,OHSAS,WCM and SAP,
Controlling of maintenance expenditure well within norms.
Coordinate the challenging of execution of maintenance related activities.
Ensure pollution free environment to improve manpower efficiency and productivity.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1
- PLANT AVAILABILITY:
Plan, Organize and monitor implementation activities for optimum plant availability in Mechanical discipline as per target to meet production from coal mill as per requirement and satisfaction of internal customers.
Coordinate the challenging of implementation / execution of maintenance activities
- Execution of preventive & corrective maintenance activities.
- Ensure periodic checking.
- Manpower planning one day in advance for daily jobs.
- Proper Job planning for shutdown jobs.
- Spare parts planning for major shutdown jobs as well as fulfilling day today basis requirements.
- Analysis of major / minor breakdowns and plan corrective actions accordingly.
- Interaction with OEM and suppliers for elimination of critical equipment problems.
- Execution of all the major jobs during shutdowns.
- Planning of contractor jobs to be carried out and raise service work order accordingly.
- Attending coordination meeting regularly for discussion of plant performance on day today basis, collecting related feedback from internal customers, communicating subordinates and assure for the execution of corrective actions
- KRA2
- Identification, Planning, & implementation of small modifications for better equipment performance.
- Proper coordination with other departments.
- Training to the workmen through workers development programs and onsite training programs for skill upgradation.
- Planning and procurement of advanced good quality tools and tackles for fast execution of jobs.
- Eliminating non value adding activities.
- Daily monitoring of equipment health and maintaining records.
- Maintaining proper housekeeping and following good maintenance practices.
- Discussion on chronic problems.
- KRA3
- I) COST CONTROL:
Plan monitor and control spares and lubricants inventory and manpower cost as per budget in Mech maintenance activities in coal mill in order to optimize the maintenance cost.
- Prepare Budget for coal mill area.
Monitoring expenditure with respect to budget.
- Classification of most critical and less critical and general spares.
Accordingly spares procurement from OEM and Reputed substitute suppliers.
- Carry out life value analysis for high value spares.
- Inspection of materials from reputed suppliers as per OEM requirement for achieving longer life of equipment.
- Monitor stores inventory reduction, standardization and optimization
- Monitoring of contractor cost comparing wi