Job Summary

To ensure the availability of Tippers Tip trailers to meet the targeted Limestone production on daily basis, monitor the budget, inventory and MTBF/MTTR to achieve the Departmental objectives.

Job Context Major Challenges

Job Context: Andhra Pradesh Cement Works (APCW) : a unit of UltraTech Cement Limited, a flagship company of the Aditya Birla Group is situated at Tadipatri, Andhra Pradesh. APCW has 2 Lines. Line1 was commissioned in 1998 with an installed capacity of 2 million tons (2 MTPA) cement annually, which has been enhanced to 2.7 MTPA over a period of six years through several improvements and modifications.

Line2 was commissioned in August 2008 with an installed capacity of 3.4 MTPA. The total cement production capacity of APCW, along with the associated Units, is 11 MTPA. The integrated plant is associated with two grinding units and one bulk terminal Arakkonam Grinding Unit (ARCW) in Tamil Nadu, Ginigera Grinding Unit (GICW) in Karnataka and Shankarapalli Bulk Terminal (SBT) in Hyderabad.

The unit has also established a thermal power plant of 2 x 25 MW capacity to cater the plant's power requirement. The APCW Mine is located near Tummalapenta Village, Kolimigundla Mandal, Kurnool District at Andhra Pradesh. It has a production capacity of 9.20 MTPA.

The mine lease extents up to 844.939 hectare. It was opened in the year July 1997. The general geology falls in Narji Limestone formation of Kurnool system, age of 800 Mio years old. As per UNFC classification, mine has got the limestone reserves of 181.65 Mio MT as on .

Winner of the prestigious National Environment FIMI Award for the year PHONE_NUMBER, it is one of the largest mines producing 9.20 Mio MTPA limestone at single location.

To improve the competency level of operators and mechanics. Reducing cost of maintenance and breakdown of Tippers. To save fuel (Diesel) Lube and consumption of spares and reduce breakdowns of HEMM aging equipment.

Key Result Areas (KRA) Responsibilities

KRA1 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 valuable practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

KRA2 System Implementation

- 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 programmes down the level team
- To know about IMS and other systems requirement and documents for NonConformity 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.

- Preparation of DPR report, MIS, M2 and M4 Notification in SAP on shift basis.

- Responsible to update QCDIP LCM.

KRA3 100% compliance of Statutory and maintaining records

- Completion of all statutory records timely for equipments

- Air receiver test, Brake test, Pollution test etc.

- To comply with the applicable statutes

KRA4 Cost Control

- (Assist superior to control maintenance costs of HEMM, LMV, Cranes etc, to optimise cost of operation and maintenance.)

- To reduce the inventory of tippers as part of cost control exercise.

- Inventory analysis using various methods (VED, XYZ, FSN, etc)

- To reduce the HSD consumption on total material handling as part of cost control exercise.

- Engine, FIP injectors overhauls and effective maintenance techniques in a phased manner.

- Control contractor over time cost.

- Better maintenance practices through PM analysis or Why Why analysis.

- Monitor fuel and lubricant consumption.

- Standardisation of the equipment to maintain low inventory.

- Introduction of fuel efficient equipment (engines) Enhance the life of the major subassemblies by quality maintenance.

- Life value analysis.

KRA5 Availability of Heavy Equipments for Mines Operations

- To ensure equipment availability as per targets.

- Proper planning of spare parts scheduled maintenance based on OEM recommendations and also conditioned based monitoring.

- To reduce the breakdown of equipment to ensure availability for operation
- To improve MTBF MTTR

- Monitor preventive maintenance schedule.

- Liase with stores for spare parts availability.

- Monitor stock availability of fuel and lubricants

- Utilisation of SAP/R3 PM (Module) for history data.

- Take steps for upgrading of existing equipment.

- Interact with OEM for major problem improvement.

- To save fuel (Diesel) Lube and consumption of spares and reduce breakdowns of HEMM equipments.

📌 PF Mines Maintenance Professional (Anantapur)
🏢 Aditya Birla Insulators
📍 Anantapur