Engineer/Sr. Engineer/ Asst. Manager Instrument

Job Purpose
Organize, co-ordinate and implement maintenance activities in 132KV ODSY, MPSS, Workshop, Plant utility and electrical equipment of DGPP to ensure uninterrupted power supply to the plant at lowest cost as per the plant requirement.

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. It is also one of the leading cement producers globally. The company has a consolidated capacity of Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants, 1 Clinkerization plant, 27 grinding units and 7 bulk terminals, post the Century merger. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.

UltraTech, Rawan Cement plant started its Line 1 operation in early 90's with the capacity of 1 MTPA, commissioned in March, 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March'2013, Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility, currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW, Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch, Germany for grinding limestone and coal, Kiln and cooler from L&T/FLS, Denmark, Combi-Grinding Cement Mill with Roller Press from KHD, Germany, Finish Grinding Slag Grinding Roller Press from Krupp Polysius, Germany, Cross belt analyser from Gamma Metrics USA for on-line analysis of Limestone, X-Ray analyser, Cem Scanner from FLS, Denmark.

As the largest cement producer in India, we continually strive to play a key role in finding effective and responsible ways to preserve the environment - a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management, energy reduction, water conservation, biodiversity management, afforestation and emission reduction which are relevant to the cement industry.

Major Challenges

• To reduce Breakdowns and motor burning for improving plant availability.
• To reduce breakdowns of HT Breakers &132 KV ODSY Equipment.
• To reduce maintenance cost.
• To Minimise impact of grid disturbances on plant operation

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Maintenance of Plant & equiments

Organise & co-ordinate all maintenance activities of 132 KV ODSY, MPSS & DGPP to ensure maximum availability of the equipment. Implement maintenance plans.

Breakdown analysis & corrective actions.

Prepare maintenance schedule for shutdown.

Plan resources for maintenance activities.

Take action on condition monitoring reports.

Ensure entry of data & history in SAP

Co-ordinate preventative maintenance activities.

Monitor stock level of spares.

Follow up with stores/purchase.

Implement the best practices.

Interact with operations.

KRA2 Cost optimization

Plan and control the cost within the budget to ensure the minimum cost maintenance. Assist HOD to prepare annual budget.

Plan expenditure with respect to budget.

Control spare consumption.

Control contract manpower and overtime.

Optimization spare consumption.

Control inventory.

Carryout life value analysis of high value items

Prepare daily power consumption report.

Keep unity and MD under control.

Identify & calibrate exhaust gas temperature and Main Bearing Temp.

KRA3 Continuous improvement. Standardization of maintenance practices.

Identification of improvement jobs through FI study & Kaizen.

Identify inefficient equipments and submit for approval to rectify deficiencies.

Implementation of approved projects.

Interact with equipment manufacturers as and when required.

KRA4 System Implementation

Ensure effective implementation all quality system e.g. WCM, TQM, ISO, EMS, Safety etc. in the area of operation to attain high productivity & quality standards. Organize & implement the quality improvement objectives.

Organize to attain WCM criteria score.

Organize to attain EMS targets.

Organize to improve the internal customer rating.

Organize & implement the safe working conditions and practices.

Implement the statutory compliance.

Organize new systems and best practices.

Organize focussed improvement studies.

Organize & implement the activities to improve OEE/MTBF/MTTR

Plan & organize to clear NCRs

Plan & organize to eliminate muda

Develop one point lessons

Carryout Why Why analysis of breakdowns.

Implement WCM campaign activities.

Plan & implement house keeping and getup work.

KRA5 People Management

Build and sustain a conductive work culture by effective management of people to improve productivity, growth and motivation levels of employees to institutionalize best practices in the unit. Effective communication.

Knowledge sharing with subordinates

Maintain discipline

Manpower planning

Appraisal of subordinates

Appraisal feedback to subordinates

Roll clarity to jobholder.

KRA6 Safety/Statutory Compliance

Implement & ensure the compliance of all

Safety and statutory requirements with respect to explosives act, electrical installations, factory etc., to improve safety. Timely preparation of reports

Keep record of energy consumption from CSEB & DGPP

Keep record of electricity duty statement

Compliance of electrical inspector report

Analyze accident and ensure corrective action.

Develop & implement procedures.

Training on safety procedures and practices.

Facilitating the processes for statutory audit