Job Purpose

Carrying out of Instrumentation maintenance activities in and Drivers. To Optimize plant availability through modification / improvement jobs in instrumentation area for cost reduction and productivity improvement.

Job Context & Major Challenges

Job Context: UltraTech Cement Limited has an annual capacity of 52 million tonnes. It manufactures and markets Ordinary Portland Cement Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It also manufactures ready mix concrete RMC.

The company has 11 integrated plants one white cement plant one clinkerisation plant in UAE 15 grinding units 11 in India UltraTech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East.2 in UAE one in Bahrain and Bangladesh each and five terminals four in India and one in Sri Lanka. UltraTech Cement is the country largest exporter of cement clinker.

The export markets span countries around the Indian Ocean Africa Europe and the Middle East.

Sewagram Cement

Works was commissioned in 2009. The plant has clinker capacity of 3.6 MTPA and cement capacity of 2.4 MTPA. The Unit has two captive power plants (CPP) CPP-I with 35 MV and CPP-II with 22.5 MV capacity.

The Unit has mines with reserve of 246.45 MT, a captive jetty, a desalination plant that can filter around 20 lakh litres of water every day and a bag-making plant. The plant also has an environmental cell which monitors air and water quality, audits, and conducts marine ecological studies and environmental studies of mines and nearby villages.

Job Challenges

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 Accountability- PLANT AVAILABILITY





Regular checking of equipments for smooth and trouble free operation of equipments for maximum availability Analyse stoppages

- Carrying out preventive maintenance of equipments.
- Attending the breakdowns of equipments.
- Analyzing results and taking corrective actions.
- Carrying out modifications required for process.
- Issuing the materials required for maintenance.
- Co-ordinating with section head for planning & execution of shutdown jobs.

KRA2 COST CONTROL & OPTIMISATION Effective utilization of available spares to reduce spare cost for maintenance.

Co-ordinating with section head in preparation of effective annual budget.

- Standardization of field equipments for cost reduction.
- Alternate material / design change, development and trial.
- Status checking of actual consumption of material with respect to budget.
- Periodic spares availability checking.
- Carrying out why why analysis.
- Carrying out the changes or modifications for power saving/spillage or leakage reduction.

KRA3 CALIBRATION Timely calibration of all field instruments

According to ISO schedule.

Calibration of temperature transmitters, pressure transmitters, kiln feed systems, belt weighers, weigh feeders, level sensors, gamma ray system and gas analyzers within the due date.

- Updating the ISO documents
- Pasting the calibration stickers on equipments.

KRA4 PLANT IMPROVEMENT / MODIFICATION Carrying out modifications as per requirement for continuous improvement in section .





Data collection & analysis

- Identifying improvement / problematic area.
- Discussion with superiors.
- Brainstorming for alternatives.
- Checking the available resources.
- Carrying out the modification within the time.

KRA5 SETTING & SAFETY Carrying out all the activities required to maintain good house keeping and safety standard of the section.

Regular checking of ESP panels and DUST COLLECTOR purging systems as per checklist.

- Regular checking of CO HIGH hardware interlock with ESP panels for the safety purpose
- Coal mill INERT GAS purging system checking.
- Identification and rectification of unsafe points and leakage points.
- Regular checking of level sensing instruments and safety interlocks.
- Impart training to workmen / contract workmen about safety.
- Checking of tools and tackles.

KRA6 SYSTEM IMPLEMENTATION Implementation of ISO / EMS / OHSAS / SA 8000 / WCM / SAP Systems in the section and effective participation in team activities.
- Identifying and executing improvement studies and kaizens

- Identification and rectification of abnormalities-
- spillage / leakages
- unsafe conditions / practices
- 5S activities
- Points emerged in campaigns.
- Carrying out implementation of quality improvement activities.
- Elimination of MUDA
- Improvement of OEE / MTBF / MTTR
- Prepare / present Weekly , monthly WCM presentations
- Develop One Point Lessons
- Updating the WCM activity Boards
- Developing Visual Controls
- Create awareness among the team members
- Creation of maintenance / break down orders
- Updation of daily check list & creation of notification and closing in SAP
- Creation / service entry of work orders
- Creation of BOM of equipments
- Creation of indents / issue passes

📌 PF Instrument (DCS&Automation) (Gujarat)
🏢 UltraTech Cement
📍 Gujarat