PF Mechanical I

Job Purpose
To support SH Mechanical in Planning, Organizing & Coordinating the implementation of Field Operation & maintenance activities (Preventive/Predictive) in LS, CR and RM for optimum plant availability within optimum cost to meet production target.

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. The company has consolidated capacity of 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

• The plant was acquired from erstwhile M/S JAL in 2015 and most of the manpower has continued and regular upskilling is required for improving the safety culture and WCM Culture at site.
• To bring cost optimization in operations by reducing the raw mill and utility power consumption and overall cost in terms of Rs. Per MT.
• Reducing unwanted stoppage due to operational issues.
• Ensuing smooth operations of Mechanical Workshop and maximizing its use for in house repair and maintenance support.

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Equioment availability

Plan organize and monitor

implementation of activities of Lime stone crusher upto raw mill hopper building inclusing LS stacker & reclaimer for optimum equipments availability for smooth running of plant. - Execution of preventive & corrective maintenance activities.

• Ensure periodic checking.
• Manpower planning one day in advance for daily jobs.
• Proper Job planning for shutdown jobs.
• Eliminating non value adding activities.
• Spare parts planning for major shutdown jobs as well as fulfilling day to day basic requirements.
• 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.
• Proper coordination with other departments.
• Daily monitoring of equipment health and maintaining records.
• Avoiding idle running of equipment's
• Discussion on chronic problems with your dept. team and & co-workers, and eliminate it.

KRA2 Reduction in plant breakdown. - Analysis of major / minor breakdowns and plan corrective actions accordingly.

• Availability of critical equipment spare parts and raising indent for procurement as per requirement.
• Plan and installation of critical equipment stand by if possible and under the cost.
• Execution of preventive maintenance activities as per schedule and equipment site condition.

KRA3 Shutdown Jobs Performing -Prepare the job list for shutdown as per priority for the plant.

• Proper Job planning for shutdown jobs.
• Planning of contractor jobs to be carried out and raise service work order accordingly.
• Spare parts planning for major shutdown jobs as well as fulfilling day today basis requirements.
• Planning and procurement of advanced good quality tools and tackles for fast execution of jobs

Kra4 Cost Control
Plan monitor and control spares and lubricants inventory and manpower cost as per budget in Mech maintenance activities * Reduction in section cost by reducing breakdowns.

• Reduction in section cost by avoiding idle running of equipment.
• Avoid over time and optimum utilization of contract manpower
• Control the handling cost by avoiding Spillage.
• Close monitoring on worker's overtime.
• Identification of maintenance cost reduction parameters.

KRA5 System Management

(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) -To implement improvement project to reduce repetitive problems/breakdown or losses.

• Timely submission of Kaizen, OPL, Good to fine, suggestion on system
• Developing and sustaining Model area in respective sections
• 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programs down the level team
• To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
• Implementation of critical spares & consumable SOP without any defilement
• Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.

KRA6 Focus on SHE (Safety, Health & Environment) along with Sustainability initiatives - Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.

• Educating team about "I know my job", "I know the hazards associated with my job and I applied control measures" & "I escalate to my senior" among manpower deployed in sections/department manpower including peer, WB & CL manpower
• Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
• To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
• Active participation in safety training, safety sub committees, standard champions meeting and any safety event
• Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc. and reporting concerned if any abnormalities for corrective action
• Adhering of all safety precautions on the site and off the site
• Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.