PF Process

Job Purpose
Supervise & monitor Kiln operations for trouble free running at optimized cost & ensure maintenance as per ISO standards. Operate & maintain process parameters as per Total Quality Integrated Management System for Kiln as to ensure uninterrupted plant production.

Job Context & Major Challenges
Job Context: UltraTech Cement Limited has an annual capacity of 52 million tonnes. It manufactures and markets Ordinary Portland Cement Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It also manufactures ready mix concrete RMC. The company has 11 integrated plants one white cement plant one clinkerisation plant in UAE 15 grinding units 11 in India UltraTech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East.2 in UAE one in Bahrain and Bangladesh each and five terminals four in India and one in Sri Lanka. UltraTech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East. Sewagram Cement Works was commissioned in 2009. The plant has clinker capacity of 3.6 MTPA and cement capacity of 2.4 MTPA. The Unit has two captive power plants (CPP) CPP-I with 35 MV and CPP-II with 22.5 MV capacity. The Unit has mines with reserve of MT, a captive jetty, a desalination plant that can filter around 20 lakh litres of water every day and a bag-making plant. The plant also has an environmental cell which monitors air and water quality, audits, and conducts marine ecological studies and environmental studies of mines and nearby villages.

Job Challenges:The major challenges to the job holder is to supervise & monitor Kiln operations for trouble free running at optimized cost & ensure maintenance as per ISO standards. Operate & maintain process parameters as per Total Quality Integrated Management System for Kiln as to ensure uninterrupted plant production.

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 1) Operation of Kiln

Operate Kiln so as to achieve the targeted production Check operation parameters of all equipments in the beginning of the shift.

¿ Identify abnormalities if any

¿ Inform process attendants for corrective actions

¿ Continuously monitor process parameters of kiln and operate kiln

¿ Register operational parameters of Kiln in log book as per the specified timelines with remarks if any

¿ Check quality parameters for operation of Kiln

¿ Identify idle running of equipment if any & take corrective actions

¿ Inform SH / HOD (Process) for any major abnormality / breakdown

¿ Perform Corrective action as per instructions of SH (Process) / HOD (process)

¿ Keep continuous overall vigil for prevention of breakdowns

¿ Coordinate with all service departments & communicate plan problems if any for corrective actions.

¿ Record shift wise production of Kiln

¿ Inform SH / HOD (Process) for production at the end of the shift

KRA2 2) Pollution Control

Operate & maintain pollution control parameters for ensuring zero tripping of ESP during plant operation & ensure fulfilment of BIS Norms Continuously check 7 monitor pollution control parameters

¿ Identify deviations

¿ Take corrective actions by self and if required with the help of service departments

KRA3 3) Plant Shutdown

Check & Inspect the equipments during shutdown and carry out repair jobs at Preheater / Kiln / Decoloriser Ensure empty out of plant area / equipment as per advice of HOD

¿ Take & give shutdown of equipment / plant

¿ Supervise opening up of Inspection manhole

¿ Inspect equipment condition & carry out repair work

¿ Ensure removal of all abnormalities before boxing up of the equipment

¿ Take trial of all equipments in coordination with all service departments

KRA4 4) Safety Assurance

Ensure implementation of all safety provisions for workmen & self Ensure use of PPE

¿ Take work permit before carrying out any job

¿ Implement all safety provisions as per SOP¿s.

KRA5 Quality Systems
Implement ISO, EMS, WCM , SA8000 & OHSAS related activities to improve productivity & quality standards. Identify and execute improvement study and kaizen.

¿ Identify & get rectify.

• Abnormalities.
• Spillage/leakages.
• Unsafe conditions/practices.

5S activities.

• Points emerged in campaigns..

¿ Execute implementation plan for

• Strategic quality projects.
• Quality improvement objectives.
• Improvement of WCM criteria score.
• EMS targets.
• Internal customer rating improvement.
• ISO system improvement.
• Statutory compliance.
• Elimination of muda.

¿ Does why why analysis.

¿ Prepare/present weekly/monthly WCM presentation.

¿ Develop one point lesson.

¿ Update WCM activity boards.

¿ Develop Model area.

¿ Develop visual controls.

KRA6 System Implementation
The system requirements of ISO, EMS, OHSAS, SA 8000 and WCM systems in thorough the involvement of employees for improving working and quality standard. Implementation of Information Security as per guideline. Identify and improvement study and kaizen.

Co-ordinate for WCM KMFA - Identify & rectify Abnormalities, Unsafe conditions/ practices. 5S activities.

Implementation Plan For
Quality improvement objectives.

Improvement of WCM criteria score.

Internal customer rating improvement. Statutory compliance.

Elimination of muda.

KRA7 Information Security
Compliance of Information Security as per Corporate ISMS guideline. Follow various ISMS policies such as Password Policy, Clear desk Policy, Internet & E-Mail Policy, Disposal Policy, Software Compliance Policy, etc.. Classify & maintain Information Assets as per guideline. Report Information Security related Incidents.

Qualification-BE in Chemical, Diploma in Cement, B.tech in Cement & Chemical

Age- 29 Years