Position Title: DH Technical Services/ Project (Assistant General Manager / General Manager / Sr.

General

Manager) Location: Sarlanagar Cement Works, Sedam Qualification: B Tech. / B E in Mechanical Engineering Job Purpose: To identify opportunities for enhancement of productivity, energy conservation, cost optimization of pre and post clinkerization section and timely execution of identified projects in Capex across Balaji. To drive initiatives to translate the opportunities into action plan and its implementation in active co-ordination with all Stakeholders. To planning, overseeing and leading project from ideation through to completion. Coordination and ensure completion of the projects ontime within budget and within the scope.Oversee all aspects of projects.Set deadlines, assign responsibilities and monitor and timely information regarding status of project To monitor and review of the health of plant rotary equipment’s and facilities to ensure uninterrupted operation of the plant and achieving the production targets with continuous monitoring program and comply with EHS (Setting Health and Safety) requirement. To ensure effective implimention of Aditya Birla Operational Excellence Framework Mangement Sytem and ISO practices through training and facilitation.

Key Result Areas Supporting Actions

Pyro-processing Energy Cost optimization of 2 clinkerization Units.

Accountability : To plan and drive initiatives for and ensure reduction of pyro-processing energy cost of 2 Units .

- Specific heat consumption of clinker across business, Actual Vs. Target, UOM – kcal per Kg clinker.
- Specific power consumption of clinker across business, Actual Vs. Target, UOM - kwh /kg clinker,
- Major initiatives taken for energy reduction, UOM – Approved Vs Implemented.

To identify potential avenues where cost effective savings could be achieved. To discuss with Stakeholders and generate and finalize the best possible options. To monitor and review performance of two kilns on regular basis and evolve solutions to address the problems and also strive to improve efficiency on a continuous basis.

Work out initiatives towards ensuring mandatory compliance requirement particularly emissions, NOx, SOx etc.

To be aware and updated on latest available technology. To select latest and best available technology for our kilns ensuring (a) plant maintainability and reliability (b) plant efficiency in terms of specific power consumption and specific heat consumption. To provide inputs and recommend technology for upcoming projects.

Diagnostic studies of Raw/Coal mills/Cement Mills for reduction in Sp.power consumption, Improvement in mill productivity, de-bottlenecking and imparting fuel/raw material flexibility.

Accountability: To perform diagnostic studies for Raw /Coal Mills with objective(s) of reduction in sp.power consumption, Improvement in mill productivity, de-bottlenecking and/or imparting fuel/raw material flexibility and to prepare and implement action plan (including capex) based on the studies.

- Rawmill/Coal mil/Cement Milll productivity – Actual Vs. Budget, UOM – TPH
- Rawmill/Coal mill/Cement Mill Sp. Power consumption – Actual Vs. Budget, UOM – kwh/T material
- Rawmill/Coal mill/Cement Mill fineness – Actual Vs. Target, UOM – % residue on 90/212 µm.For Cement Mill:Blaine in M2/Kg

To monitor and review AS-IS performance mapping of all grinding mills (Raw/Coal/Cement mills)



To monitor and revirew of day to day performance of grinding mills through MIS, to seek clarifications from stakeholders in case of deviation from desired performance level, to analyze reasons for sub-optimal performance of the grinding mills, to recommend action plan for improvement in objective(s)

To monitor and review diagnostic study/plant audit for grinding mills for improvement in productivity, energy efficiency and de-bottlenecking.

To ensure implementation of recommended actions plans.

To review capex requirement arising out of recommended action points.

To hold technical discussions with various suppliers for finalization of concept/scheme, project scope, deliverables etc.

To evaluate capex replacement/modification aimed at performance improvement of grinding mills in terms of productivity/energy efficiency To validate Baseline performance and Performance Guarantee after capex installation.

Timely execution of sanctioned projects of SCW unit

Accountability: Project Engineering, execution and monitoring or improved plant performance, plant reliability and productivity, coordinate for conceptualization feasibility study, planning and organizing capex for achieving upgradation, process improvement, plant relaibility by bridging technological gap. Ensure timely completion of capex and major modification within budgeted cost to achieve targeted results.

- Achievement of replaced/modified equipment performance parameter in PG test– Achieved Vs. Guaranteed, UOM- refer supporting actions.
- Timeframe for reaching guaranteed parameters of the equipment replaced/modified – Actual Vs. Agreed, UOM – No. of Days.
- Issues cropped up during equipment operation. Actual Vs Target Zero, UOM- Number

To coordinate internal resources and third parties/vendors for flawless execution of projects. To ensure that all projects are delivered ontime, within scope and within budget.

To facilitate to define the project scope and objectives, involving all relevant stakeholders and ensuring technical feasibility.

To ensure resource availability and allocation.

Develop detailed project plan to monitor and track progress.

Manage change of project scope, project schedule and project costs using appropriate verification techniques.

Report and escalate to management to minimize project risks.

Perform risk management to minimize project risks

Delegate project tasks based on team members individual skill sets and experience level.

Track project performance, specifically to analyze the successful completion of short and long term goals

Meet budgetary objectives and make adjustments to make project constraint based on financial nalysis.

Aditya Birla Operational Excellence/ISO system monitoring, review and implementation.

Accountability: To overseeing on implementation, sustain and continual improvement of following ABOEF process requirements across SCW To steer proper compliance & Implementation of IMS standard :Ensure the effective implementation of various management systems viz.



ISO 45001 & ISO 50001 in the plant as per the standard requirements & other guidelines.

- Compliance against various WCM audits (5S, BCE, Hygiene etc.).

Actual Vs. Target, UOM – %
- Slippage in Conducting the monthly GRT & KFA meeting

Actual Vs. Target: Zero, UOM – % Compliance
- Compliance of IMS & ISO 50001 Internal/External Audit findings closure:

Actual Vs. Target: Zero, UOM – % Compliance A :Facilitate SCW unit on implementation, sustain and continual improvement of following ABOEF process requirements:

- improvement in internal customer satisfaction.
- Develop & drive maintenance strategy & autonomous maintenance.
- Visual development.
- Knowledge upgradation.
- Team performance & monitoring WCM MIS.
- Ensure 100% compliance against various WCM audits(5S,BCE, Hygiene etc.).
- Process improvement.
- New technology adoption & development.
- Evaluation of Kaizens and suggestions judicially.

B : Ensure proper compliance & Implementation of IMS standard:

- Policy Implementation.
- Document verification.
- Ensure zero Non Compliance in internal & External system audits.

4 : Mentoring & Drive the associated KFA & GRT as per the ABOE framework & CWCM guidelines. 5 .Encourage team and give them the improvement projects & Kaizens to enhance performance & productivity.

Creating implimenting and monitoring Condition Based Maintetnace(CBM) programs

Accountability: Plant Availability : Organize NDT test for critical machines and analyze results to recommend necessary action for improving plant availability.

Technical Support : Coordinate for checking of correctness of technical specification of indents, updation of PM & MM moudle of SAP for right procurement, inventory control review of PM schedule and equipment history.

- MTBF/MTTR/OEE of unit operations of TPP, pre and post clinkerization (excluding Packing)

MTBF & MTTR Actual Vs. Target, UOM – Hours. OEE : Actual Vs. Target, UOM – %
- Preventive Maintainance Order(PM-07)

Actual Vs. Target, UOM – % completion
- M-2 notification (Why’Why Analysis).

Actual Vs. Target, UOM – % completion To monitor and review reliability based system including preventive maintenance systems, vibration analysis and condition monitoring. To facilitate preventive maintenance programs (Inspection, Vibration, Oil Analysis, NDT, thermography etc.) to ensure optimum equipment availability To overseeing in the creation of preventive maintenance routine and bills of materials (BOM) for new equipment.

To steer for preventive maintenance work order system with coordinated execution of the area operations and maintenance team

- To take a lead role in analysis and elimination of repetitive problems through root cause analysis, Pareto analysis, statistical review, FEMA and similar technique
- Responsible for the facilitation of continuous improvement processes around equipment availability and reliability.
- To support and guide sustainable improvements in MTBF of major equipments
- Provide ongoing reports as needed on the condition based monitoring program status
- Research solution to technical problems.

- To overseeing SAP system operations in the area of preventive maintenance routine and development with concerned HO SAP team
- To organize technical support training and development of maintenance functions with specific fous on the enterenching reliability concepts within the maintenance group
- To ensure Life value analysis of major items

📌 DH Technical Services/ Project(Location: Sarlanagar Cement Works, Sedam) (Telangana)
🏢 UltraTech Cement
📍 Telangana