DH Quality Control

Job Purpose
To plan and monitor, inspection & control of material & mix at all stages in manufacturing processes and facilitate the plant in producing optimum quantity and consistent quality of products for enhanced organizational productivity at all times

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 a consolidated capacity of Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals.

Maihar Cement Works is a modern cement plant with a high level of automation, computer-aided data acquisition & sophisticated control system, which ensures quality at every stage of production. The Unit is strategically located at Sarlanagar at a distance of about 8 Kms from the town of Maihar on Maihar-Dhanwahi Road in Satna District of Madhya Pradesh. About 45 Kms South-East of Satna, a hub of Cement Industries in India. Maihar is situated at the Main Railway line of Howrah-Mumbai. It is one of the famous dots in the mythological map of India and also regarded as the abode of Goddess Sharda.

The Unit has a clinker production capacity of 3.0 MTPA, Cement Production capacity of 4.2 MTPA & manufactures OPC 43, OPC 53 & PPC grade of cement with Environment clearance for cement production capacity enhancement to 6.0 MTPA. Unit also has a solar power plant of installed capacity 12.5 MW DC / 8.75 MW AC and is equipped with the latest technology & equipment's. The Normal Power requirement of the Unit is about 47.5 MW which is being met through our two nos. TPP of a total capacity of 2 x 15.7 MW. We have also a contract demand of 22 MVA with MPPKVVCL.

There are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff ColonyThere are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff Colony.

The position holder is critical to supervise and coordinate with Technical, Mines, Commercial and marketing departments for overseeing the Clinker and Cement manufacturing procedures to ensure that products (Raw material and Finished product) meet quality and comply with the statutory compliance standards by leading and guiding quality related aspects in the Unit. The position is also critical for managing external stakeholders like Government agencies, consultant and vendors.

Major Challenges

• Market fluctuation often pose challenge in inventory management specially in optimal resource utilization
• Dynamic raw mix has complexities associated with it in terms of using industrial waste, other alternate materials hence hazard management, meeting strength criteria and market demands becomes challenging
• Anticipating customer impact with using different compositions of raw material.

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Optimization Of Raw Mix

• Monitor consistency of raw mix compatible with available fuel for productivity & cost improvement.
• Plan for medium and long term considering maximizing inhouse or local sources.
• Plan for optimal utilization of mines limestone and own clay - Plan with Mines & Material team for required quality of limestone & additives at low cost
• Plan usage of low-cost fuels.
• Recommend and implement quality control methodologies in coordination with Technical and Process department
• Plan for adding additives for required quality & consistency
• Oversee testing of deposit as per mines team requirements and plan for consumption based upon mines reserve/deposit life.
• upon mines reserve/deposit life.
• To ensure R&D efforts for betterment of product and raw materials (Product development).
• To associate with different trials for cost control i.e. use of AFR, Pet coke/ different additives in Clinker and Cement Grinding.
• Monitor LSF standard deviation in limestone stock pile as well as in kiln feed

KRA2 Quality of Coal, Raw material, AFR & Packing bags

• Plan and monitor implementation of quality control/assurance system for ensuring 100% conformance of quality for GU, Marketing requirements - Oversee inspection & control of incoming materials, in process materials and finished products as per quality plan.
• Monitoring ratio of material used basis established parameters
• Enable provision of finished goods in accordance with Government norms and UTCL Standards.
• To associate with concerned HODs for quality assurance.

KRA3 Legal And Statutory Compliances

• Monitoring compliance of legal requirements pertaining to quality & art work of bags -Plan for proactive renewals and monitor compliance of BIS requirements with implementation at QC laboratories 100% with zero tolerances.
• To ensure all activities related to ISO/BIS of the Labs. To ensure the maintenance and Calibration of Chemical and Physical laboratory Equipment of the Labs.
• To keep close liaison with statutory authorities & timely renewal of all licenses.
• Facilitating internal and external audits and ensuring no non-conformities

KRA4 Cost Optimization

• Planning effective utilization of resources for optimizing costs -Enable identification of cheaper sources /types of fly ash
• Analyze use of Alkali bypass by various means (Like addition in cement, raw mix additives, in TPP and Sale)
• Power consumption optimization through controlled monitoring Blaine & residue

KRA5 System Implementation
(Coordinate, organize & monitor effective implementation of IMS and other systems in the department for improvement of productivity and creating safe work culture) -To facilitate department activities to implement, sustain and continual improvement of internal & external customer satisfaction score, developing & drive maintenance strategy along with autonomous maintenance, visual development, knowledge upgradation, process improvement.

• Ensuring respective assigned team performance & monitoring WCM (ABOF) MIS regularly for 100% compliance against various WCM audits/assessments (5S, BCE, Hygiene etc.) & timely evaluation of Kaizen & suggestions in system
• To ensure timely compliance & implementation of IMS & other standards requirements like creating awareness among team on systems policy, implementation, document verification for zero non-conformity or OFIs in internal & External system audits/assessment.
• Mentoring & driving associated KFA & GRT as per the ABOE framework & WCM guidelines
• Encouraging team for improvement projects & Kaizen to enhance performance & productivity along with bringing and adopting new technology projects & its development actions.

KRA6 Safety Excellence
Implementation of all applicable Safety Standards without any Deviation including Safety, Health & Environment Management  100% implementation of all applicable safety standards in department with target of zero injury and no hazard to men, machinery, environment and health of employee deployed in respective department

 To ensuring whoever is working in department from top to last person should be aware of the Job they are performing, associated hazards and measures to perform the jobs safely while escalating unsafe acts and behaviours to their seniors.

 Implementation, adherence of Progressive Consequence Management and taking needful action.

 Effective contribution in respective safety subcommittee (100% Compliance), daily walkthrough round (04 WTI Per Month), be visible felt leader and sharing views in apex safety meeting for building and inculcating strong culture of safety.

 Ensuring self and team timely report or submit SO (04 SO Per Month), any incident or accident along with taking analysis and corrective actions in respective systems.

 Achieving CFSA Severity Index below 2.5 for project & shutdown jobs

 Ensure to completion of abnormalities observed and reported in daily walk through across department.

 Adhering of all safety precautions on the site and off the site

KRA7 People Management & Development
To build & sustain a conductive work culture within department to improve productivity, growth & improvements in department performance for overall objective of unit along with motivating employees to institutionalize for bring innovation, creativity, best practices to replicate in the Unit by effective management of people for development of them '- Guiding team of SMART and differentiating Goals Setting aligning with Unit and Business targets, time to time review performance and giving or seeking quality real time constructive feedback on performance appraisal and other areas. Rewards and recognition without any biasness.

• Developing Team for multiskilling for next role through the 70:20:10 Model for Learning and Development and drafting SMART MDP's for all team members.
• Having regular communication that count with maintains transparency for top to down communication (mentoring, coaching, counselling, recognition etc.)
• Developing interpersonal skills, maintain discipline, adhering ABG Values and systems, handling and resolving grievances and good rapport building with other colleagues within function or cross function
• Encouraging them for taking lead in Unit, Business or Group level projects and contribute for growth
• To identify common training needs of team for building competency for current and future requirement of organisation
• Optimisation of manpower by giving opportunity of Job Rotation, Enriching & Enlargement of Jobs time to time along with recommending for internal or external training for skill behavioural/productivity improvement.

KRA8 Liaison: Ensure and organise timely renewals of licences and consents with BIS and Pollution control boards Regular meetings and develop good networking with concerned department and officials.

KRA9 System ImplementationEnsure implementation and review of quality management systems of ISO 9000/ EMS/WCM/NABL implementation in the department.

Attainment of quality improvement objectives.

Attainment of WCM criteria score.

Attainment of EMS targets.

Improvement of Internal customer rating.

Improvement in ISO system.

Safe working conditions and practices.

Statutory compliances.

Identify & formulate implementation plan for New systems and best practices.

Focused Improvement Studies.

Clearing NCR's in time.

Improvement in OEE/MTBF/MTTR Elimination of MUDA.

Conduct awareness programmes.