SME Mech Jetty

Job Purpose

• Lead, manage, and Oversee All Port Equipment Assemblies (Port Cranes, Pipe conveyor and other specialized assemblies) to enhance asset integrity and reliability, improve equipment performance, solve chronic issue
• Overseeing all Design Engineering, Feasibility studies, Technological advancements and sustainability initiatives, crucial in supporting Jetty Operations with focus on predictive approach, ensuring that ports remain functional, safe, and efficient.
• To strengthen the capabilities of AETs/DMTs to successfully implement the strategic maintenance management framework for long-term asset care and provide technical expertise and training to maintenance personnel on Preventive, CBM methodologies and best practices.
• Ensure all statutory, regulatory, OEM and Marine Compliances for Critical Mechanical Assets governing port operations and safety standards.

Job Context & Major Challenges
Job Context
The job is responsible for advancing technology and ensuring the reliability and safety of Mechanical systems across the Jetty To remain at the forefront of innovation and progress, conducting feasibility studies and technical assessments for green field/brown field projects, collaborating with other SME's, PBUTs and stakeholders to integrate mechanical systems with all technological Projects. To conduct design work, projects plan, and consult with clients and colleagues and oversee installations, conduct inspections, and troubleshooting on-site issues, supervising the operation and maintenance of Mechanical systems and machinery. To provide valuable consultation services and training to AET/DMT to perform routine Planning and budgeting, annual shutdowns, maintenance checks and troubleshooting issues as they arise.

• The role is to ensure the optimal performance and longevity of Grab unloader (26 MT capacity, 2 no's), Hydraulic winch (120 MT capacity of 4 no's), Conveyors (Trough & Pipe, 7km long), Sulphur acid line (3.5 KM), Copper concentrate Weighing & sampling system and other specialized critical equipment's, ensuring that the jetty remains in optimal condition, minimizing downtime and operational disruptions.
• The job is responsible for advancing technology and ensuring the reliability and safety of Mechanical systems and to remain at the forefront of innovation and progress, conducting feasibility studies and technical assessments for green field/brown field projects, collaborating with other SME's, PBUTs and stakeholders to integrate mechanical systems with all technological Projects.
• To provide valuable consultation services and training to AET/DMT to perform routine Planning and budgeting, annual shutdowns, maintenance checks and troubleshooting issues as they arise.
• The role will develop and implement a comprehensive CBM program for port cranes, including the selection and integration of appropriate tools and technologies. Prepare detailed reports and presentations on the performance and outcomes of the CBM program, highlighting key metrics and areas for improvement. Stay abreast of industry trends and advancements in CBM technologies to continually enhance the effectiveness of the maintenance program.
• Conduct regular inspections and audits of crane equipment to validate the accuracy of predictive models and adjust maintenance plans accordingly.

Job Challenges

• Ports are exposed to harsh environmental conditions such as saltwater corrosion, storms, and extreme weather, all of which can accelerate wear and damage.
• Keeping up with technological advancements in port operations and machinery requires continuous learning and adaptation.
• Ensuring adequate funding for maintenance activities while balancing the financial constraints of port operations can be challenging.
• Navigating the complex landscape of regulations and ensuring compliance with environmental, safety, and operational standards is critical.
• Keeping up with rapid technological advancements and industry changes, as most of the plant has served its life and started becoming obsolete.
• Balancing the need for innovation with complete acceptance by PBUT and adoption by AET/DMT
• Expanding the expertise and skill of DMT and AET, through continuous education and training, by developing Programmes based on team capability and understanding
• The age of most of the equipment that need upgradation.
• Critical maintenances with greater degree of difficulty as it is a Single line process, Pipe conveyors connecting the plant with the jetty.
• Handling of hazardous sulphuric acid is critical from the safety point of view owing to its toxic nature necessitating greater safety precautions.
• Blend of old and new technologies adapted from time to time possess challenge due to complexity of varied variety of equipment in the system.

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Daily Asset Care

• Ensure preservation of maintenance spares & equipment in coordination with AETs.
• Use ERP to maintain & monitor following and assist daily asset care:

 Calibration / overhauling & breakdown / corrective maintenance, data related to 'Critical Process Equipment's'

 Implementation of 'Work Order Cycle' to different agencies / departments by daily logbook keeping, recording maintenance record, etc.

 Structured data / check sheet for equipment details, job plan, safety plan, etc.

 Data related to maintenance history, jobs undertaken, and details of spares & consumables utilized.

• Develop resource, time and cost estimates for planned maintenance, collaborate with AET maintenance members to schedule manpower & other resources, and identify critical path & associated contingencies for effective outcome.
• Ensure effective utilization & control of manpower, overtime, and store expenses through recycling spares and waste reduction.
• Plan & control the direct and indirect maintenance costs associated with PBU & AET operations, monitor maintenance expenses against budget in order to achieve better cost control and improve profitability.
• Partner in P&B for CAPEX and Spare inventory for all maintenance (E&I and Mechanical), and digitalization activities for the financial year.

KRA2

• Set & communicate clearly defined KPIV & KPOV (Key Performance Input / Output Variables) of asset care to AETs & DMTs with all the related costs.
• Float multiple inquiries & review the proposals for Capex projects / Overhauling / Refurbishing work and suggest vendor accordingly.
• Support standardization of spare parts & consumables, control of inventory & expense, and vendor development & management to reduce spare inventory cost, thereby reducing working capital and improving profitability.
• Monitor & review Daily Performance Indicators (DPIs) of AETs and DMTs across Vertical periodically to provide necessary support to excel in their performance and take necessary corrective & preventive actions for deviation.
• Execute PM Plan as per CoE - Asset care guidelines, analysis of equipment performance gap and implementation of recommendations, and monitor PM quality to attain higher availability and sound health of equipment.

Provide technical advice and monitoring to AET & DMT members with respect to adherence to maintenance practices & programs and escalate non-compliance to PBUH / VH.

KRA3 Customer Centricity

• Identify areas of improvement and provide solutions for continuous improvement (QCDIP) in maintenance and achieving customer satisfaction.
• Partner with internal customers to achieve KPIs and ensure timely maintenance support.
• Generate MIS reports of KPI analysis with respect to maintenance cost and process & equipment performance for the reference of all internal customers.
• Facilitate AETs in chronic problem resolution & failure analysis and build troubleshooting / structured problem-solving capability in AETs & DMTs across Vertical.

KRA4 Reliability Centered Maintenance & Asset Life Improvement

• Ensure formulation, review and implementation of Standard Maintenance Practices across all PBUs.
• Oversee implementation of appropriate maintenance practices and arrange adequate resources such as labor and spare parts, to minimize the equipment downtime.
• Achieve zero production loss due to equipment related breakdowns by following measures:

 Ensure availability of critical spares

 Use ERP System (Ekayaan) and ensure complete adherence with maintenance schedule.

 Conduct Equipment Criticality Analysis to identify gaps & anticipate issues proactively and recommend solutions.

• Improve uptime / equipment availability through preventive & predictive maintenance, shutdown & overhaul, and breakdown maintenance with help of AETs & DMTs.
• Monitor the progress on condition appraisal for all equipment, sub equipment and assemblies and ensure that condition appraisal & refurbishing of equipment is happening as per the plan.

KRA5

• Develop strategies to enhance asset integrity (e.g., TPM, JIPM, RCM, etc.), sustainability and longevity of Plant machinery & equipment through Heat maps, to increase reliability across its lifetime.
• Scrutinize the system capability & infrastructure and propose improvements for scope of digitalization, equipment reliability, predictive maintenance capability, equipment health monitoring, and adapting new age technologies like Artificial Intelligence.
• Undertake following measures for a successful shutdown & overhaul job:

 Partner with PBU, in planning & execution

 Ensure availability of spares, skilled manpower, special tools & tackles, etc.

 Implement PERT / CPM network for different phases of the job

• Ensure that corrective actions as per the performance gap analysis are incorporated and implemented, for continuous improvement.
• Design & oversee the implementation of process control and conduct analysis for any process deviation / control issue from the control strategy for effective maintenance.

KRA6 Asset Life Cycle Management

• Develop systems & strategies to ensure standardization of Asset Care practices / processes from consistency and enhanced reliability point of view
• Work closely with Maintenance Execution teams, operating teams, and management to help define Asset life-cycle management plan.
• Develop a robust measurement system to assess the reliability of plant and equipment.
• Implement systems and processes for effective spare inventory management (XYZ analysis, VED analysis, suggest for VMI, PMA [Parts management agreement] for PLC items, Virtualization of server & clients, etc.)
• Review, analyze and monitor trends & systems in maintenance management framework to recommend actions for continuous improvement and achieving customer satisfaction.
• Create standards for daily autonomous maintenance of equipment on the basis of routine checks (CLTI, SWI, etc.) and define Autonomous maintenance practices for operators.
• Conduct periodic audits to identify the areas of improvement for maintenance framework execution and Electrical & equipment upgradation projects in consultation with CoE Head Asset Care.
• Implement Predictive maintenance practices & condition monitoring for increasing the asset life span as well as reliability across its life time.

KRA7 Value Creation & Asset Leadershi

• Develop alternate vendors and focus on indigenization of imported items to minimize cost & diversify vendor portfolio.
• Restore equipment to ideal condition, set up mechanism to monitor & improve asset care indices (MTBF, MTTR, OEE etc.), and undertake Capex projects to improve maintenance costs through Total Lifecycle cost approach.
• Develop plans for technology upgradation, Electrical Equipment for long term sustainability of operations and maintenance in the Vertical.
• Benchmark best practices for Industry 4.0 based Electrical projects and asset life cycle improvement.
• Conduct periodic audit to review 'As Is' state and suggest for 'To Be' state of Asset Care practices & processes for taking them to next level of excellence / maturity.
• Identify area of opportunity and conceptualize & execute projects for OEE improvement, technology upgradation, low cost Electrical, maintenance cost optimization, digitalization (FI / PI / JDI), etc. to create maximum value for the Vertical.

Control overall cost of maintenance by following measures: track spare consumption by conducting regular reviews, control spare inventory at optimum levels, explore possibility of using import substitutes and undertake other innovative cost optimization projects.

KRA8 Capability Building & People Engagement

• Monitor & review the performance of AETs & DMTs periodically and provide feedback, coaching and mentoring to excel in their performance and build Equipment & Process related capabilities with help of CoEs.
• Develop Pre & Post Shutdown report for gap identification and remedial actions and share the lessons learned with O&M team for future shutdowns.
• Set up a robust mechanism of skill enhancement for various asset care practices (Autonomous, Planned & Predictive Maintenance, etc.) and build capabilities pertaining to Asset Care methodology, Future Maintenance practices, digitalization, and Industry 4.0 applications.
• Build Asset care capability across the Vertical by institutionalizing and training AET & DMT members in best maintenance practices & programs (TPM, FMEA, JIPM, etc.)
• Embed Industry 4.0 digital work culture to increase the work efficiency and overcome resistance to technological change.
• Identify and address capability gaps according to requirement of different roles and train / handhold AETs to do the same.
• Create forums & platforms for the following:

 Two-way communication with employees (including contract workmen, supplier and any other key stakeholder.)

Active interaction of AETs & DMTs across PBUs within the Vertical.