- Job Purpose
- Responsible for key functions & proper maintenance of SAP1 (Electrical &
- Instrument) and condition monitoring of equipment, performance, and health to predict potential issues. Also Daily work management, continuous improvement, and value creation at business level as per planning and budgeting, Environment, health, and safety norms and driving for sustainability.
- To collaborate with AET, digitalization, planner, reliability & digital cell and shared services and leverage their expertise to achieve aspirations and capability building of the team to achieve defined ROAD map fulfilling both short term and long-term objectives of PBU.
- To maintain proper planning, scheduling and coordinate maintenance activities, including breakdowns and shutdowns.
- To ensure continuous improvement to happen by identifying opportunities for improvement and implement changes to increase efficiency, reduce costs, and enhance safety.
- To assist my team to maintain accurate records of maintenance activities, equipment history, and spare parts inventory. Also collaborative work with operations, production and quality teams to optimize plant performance.
- Dimensions:

Business/SBU/Unit Revenue 50000/35000/15000 cr.

Business Workforce Number

MG 368, LMS 69. OG 1042, Cont 2881

Unit Workforce Number

Staff(Management &
- LMS)- 437

Workmen- 1042

Contract Workmen- 2881

Function Workforce Number

Staff: 132 (Management), 95 (LMS)

Company Workmen: 433

Contract Workmen: 659

Total Strength: 1319 Nos

Department Workforce Number

Staff: 42(Management), 41 (LMS)

Company Workmen: 158

Contract Workmen: 126

Total Strength: 367 Nos

Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter

Copper Anode Production- 171969 T

Acid Production- 430000 T

P&B; Cr. Copper 1

Stores Expenses- 5.37 Cr

Contract Expenses: 8.62 Crs,

Capex Budget: Variable Crs

Job Context

Birla Copper unit at Dahej is a copper smelting operation having two operational copper smelters to process blended copper concentrates of varying specifications to supply copper in the form of anodes of 99.5% purity to the refineries attached to them. This position is responsible for operation and maintenance of Converter/WIP of Copper Smelter 1 supplied by Outotec. This is the most proven and reliable semi-continuous copper smelter technology.

Key aspects of this role are analyzing and understanding the SAP1 operation and maintenance.

Job Challenges

- The continuously changing raw material (copper concentrate) profile and varying quality results in fluctuation in matte grade for converter furnace operation
- Operational issues impacting plant availability
- The process of accurate sampling, analysis and metal accounting becoming very complex
- SAP1 PLC,



DCS detailed understanding & troubleshooting awareness, All the critical spares database with pilog code &
- Stock check fortnightly.
- Ensuring maintenance activities comply with safety protocols, regulations, and industry standards.
- All the spares database to be made with New Pilog code &
- Stock status - Shopfloor &
- Store - Inventory review
- Repair and Replacement of damaged or worn-out parts such as transmitter, control valves, etc, components, and equipment.
- Plant is old and needs day to day maintenance work for achieving plant uptime.
- Process is hazardous with corrosive, toxic emissions, minimizing emissions within PCB norms and meeting other environmental and safety norms difficult.
- Identifying and resolving equipment malfunctions, faults, and breakdowns.
- Ensuring compliance with industry standards, regulations, and environmental requirement, etc.
- Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

- Production

To deliver required with quality as per anode furnace requirements and P&B.;
- Manage the operations, and maintenance (Electrical &

- Instrument).
- Ensuring a safe working environment and compliance with safety regulations.
- To implement asset care practices for availability and reliability as per P&B; in PBU.
- Ensure the effectiveness of HIRA, JSA SOP and SMP and analyse and review/update for appropriateness of SOP/SMP.
- Cost

To be cost efficient

- Ensure budgeting considering the annual business plan.
- Review and monitor direct and indirect costs and ensure spending within P&B.;
- Ensuring achievement of cost saving without compromising quality and delivery by driving cost-saving initiatives, other major initiatives for reducing production costs and de-bottlenecking.
- Ensure Implementation of FI projects as per the structured process.
- Cash
- To improve working capital
- Energy power reduction by controlling process and mechanical equipment’s by required logic modification in system.
- Identification of high energy consuming equipment & its detailing to be done with possibility of energy saving.
- Expenses & procurement to be within the budget by maintaining all critical spares of Sap1 in line with P&B; excluding any unplanned requirement with special approval.
- Customer Centricity

Fulfil internal & external customer expectations for satisfaction and reliability, cost, and delivery





- Achieve Overall equipment availability & reliability of SAP1.
- Ensure implementation of the action plan as per feedback from internal customer satisfaction surveys.
- Collaborate with the customer and COE-Process Care to ensure the supply of quality products within the limitations of varied raw material quality.
- Drive customer centricity as a culture in the team.
- Managing and monitoring the logic related issues and as per the process requirement doing the modifications.
- Sustainability &
- Compliance

Develop and implement the roadmap for sustainable practices

- Ensuring compliance with all statutory and environmental norms in AET.
- To develop a roadmap for achieving plant/ business aspirations and ensure its implementation for short-term and long-term sustenance.
- To develop Heat Map, prioritize the areas for improvement and ensure its implementation as per plan.
- Ensuring compliance with statutory norms and HIL standards for Occupational Health, safety, and workplace etc.
- Ensuring that the workplace is in order with respect to all Sub-areas (Level of 5-S).
- Ensuring compliance with the Integrated Management System and Energy Management System
- Safety, Health, and Environment

To ensure zero harm by building a culture for safety and valuing Human Lives
- Embedding a safety culture by spreading awareness to build a safety culture, implementing safety standards, developing safety mechanisms, and ensuring safety-related training is imparted to achieve zero harm by working in close coordination.
- Ensuring e mergency handling readiness of all cross-afunctional teams across the PBU.
- To create a safe work environment by designing/re-engineering/Continuous Improvements.
- People development and engagement

Building Capabilities of Employees and enforcing a culture for people development and sustainability

- Ensuring all people development processes driven by the business are implemented in the AET
- Monitoring intake and deployment of the appropriately trained contractual workforce and ensuring their continuous training and well-being as per company guidelines
- Monitoring and improving the performance of team members by capability building.
- Driving interdepartmental mobility through multiskilling.
- Reviewing, monitoring, and ensuring implementation of all action plans as an outcome OHS/Dipstick survey to develop leadership pipelines and improve team engagement scores.
- To motivate and ensure engagement and involvement of all team members with enhanced morale.
- Role Specific Competencies

Technical competencies
- Degree in Engineering preferably Instrumentation and control.
- Knowledge of DCS, PLC and SCADA, & associated equipment’s

Behavioural competencies
- ABG Leadership Competencies

📌 AET Mbr Inst SAP 1 (Gujarat)
🏢 Aditya Birla Group
📍 Gujarat