Job Purpose

To support SH Mechanical (RMH & Utility) in Planning, Organising & Co-Ordinating the implementation of Field Operation &maintenance; activities in RMHS for optimum plant availability within optimum cost to meet production target, Execution of improvement / modification jobs for cost reduction and productivity improvement along with manpower planning and spare parts management, system implementation for best practices by ensuring pollution free and safe working environment.

Job Context & Major Challenges

Job Context:
Andhra Pradesh Cement Works (APCW) : a unit of Ultra Tech Cement Limited, a flagship company of the Aditya Birla Group is situated at Tadipatri, District - Anantapur. APCW has 2 Lines. Line-1 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. Line-2 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 4 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 hector. 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 31 March 2012. it is one of the largest mines producing 9.20 Mio MTPA limestone at single location.
The focus area for Job holder is to ensure operation and maintenance activities of Raw Material Handling section in the Plant and ensuring availability of mechanical equipment’s to deliver desired quantities of raw material for plant operations. The position is also responsible for providing timely and accurate information to Management for taking strategic decisions, co-ordination with technical teams and supervising over the activities of team members.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)KRA1PLANT AVAILABILITY:
Plan,



Organise and monitor implimentatin activities for optimum plant availability in Mechanical
Descipine as per target to meet production from cement mill as per requirement and satisfactionof internal customers.
Coordinate the challenging of implementation / execution of maintenance activities Execution of preventive & corrective maintenance activities.
Ensure periodic checking.
Manpower planning one day in advance for daiy jobs.
Proper Job planning for shutdown jobs.
Spare parts planning for manjor shutdown jobs as well as fulfilling day to day basic requirements.
Analysis of major / minor breakdowns and plan corrective actions accordingly.
Interaction with OEM and suppliers for elimination of critical equipment problems.
Execution of all the major jobs during shutdowns.
Planning of contractor jobs to be carried out and raise service work order accordingly.
Attending coordination meeting regularly for discussion of plant performance on day today basis, collecting related feedback from internal customers, communicating subordinates and assure for the execution of corrective actionsKRA2Identification , Planning, & implementation of small modifications for better equioment performance.
Proper coordination woth other departmets.
Training to the workmen through workers development programmes and onsite training programmes for skill upgradation.
Plannig and procurement of advanced good quality tools and tackles for quick execution of jobs.
Daily monitoring of equipment health and maintaining records.
Maintaining proper housekeeping and following good maintenance practices.
Discussion on chronic problems.KRA3COST CONTROL:
Plan monitor and control spares and lubricants inventory and manpower cost as per budget in mech maintenance activities in coal mill in order to optimize the maintenance cost. Prepare Budget for RMHS area.
Monitoring expenditure with resoect to budget.
Classification of most critical and less critical and general spares.
Accordingly spares procurement from OEM and Reputed substitutensuppliers.
Carry out life value analysis for high value spares.




Inspection of materials from reputed suppliers as per OEM requirement for achievinglonger life of equipment.
Monitor stores inventory reduction , standardisatin and optimization
Monitoring of contractr cost comparing wth last year expenditure.
Close monitoring on workers overtime.
Planning odf spare parts and raising indent for procurement as per requirement.
Identifcation of maintenance cost reduction parameters.KRA4System Management
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)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 programs down the level team
To know about IMS and other systems requirement and documents for Non-Conformity 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.KRA5Focus on 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 good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

📌 PF Mechanical (Rclmr & Trans) - Engineer/Sr Engineer/Asst. Manager (India)
🏢 Aditya Birla Group
📍 India