Blast Furnace - Area Incharge (Electrical)

JOB DESCRIPTION (JD)1. Position Details

ParticularsDetails

Position Name Blast Furnace Electrical Area In-Charge (Electrical Maintenance)

Department Iron Making

Organization JSW Steel Ltd.

Location Vijayanagar

Reports To Section In-Charge

• Job Purpose To ensure the safe, reliable, and continuous operation of Electrical, Instrumentation, and Automation (E&I) systems by achieving production and business plan targets, improving equipment reliability, and driving effective maintenance practices. The role requires close coordination with Operations, Mechanical Maintenance, and Control Room teams while ensuring compliance with safety standards, statutory requirements, and environmental norms.
• Role Summary The Electrical Area In-Charge is responsible for ensuring the safe, reliable, and continuous operation of electrical systems in the assigned area through effective management of preventive, predictive, breakdown, and shutdown maintenance activities.
  
  

The role focuses on improving equipment reliability through the implementation of Equipment Failure Mode and Effects Analysis (EFMEA) and Root Cause Failure Analysis (RCFA) actions, ensuring the availability of critical spares, optimizing inventory, and driving effective utilization of the SAP Plant Maintenance (SAP PM) module.

The position also involves shutdown planning and execution, coordination with Operations and Mechanical Maintenance teams, and strict enforcement of corporate safety standards to achieve zero-incident operations.

• Key Responsibilities4.1 Operations and Maintenance
• Ensure the safe, reliable, and continuous operation of Electrical, Instrumentation, and Automation systems to support production targets and plant availability.
• Oversee maintenance, troubleshooting, and optimization of E&I systems, including:
• Process Instrumentation: Pressure, temperature, flow, level, and analytical instruments.
• Control Systems: PLC, SCADA, DCS, servers, and industrial networks.
• Electrical Systems: Motors, drives, Motor Control Centres (MCCs), power distribution, and protection systems.
• Develop and implement preventive, predictive, and breakdown maintenance strategies to minimize downtime, enhance equipment reliability, and improve overall system performance.
  
  

4.2 Equipment Reliability and Failure Analysis

• Drive equipment reliability improvement initiatives by implementing robust maintenance practices, ensuring the availability of critical spares, and developing redundancy for critical equipment to improve Mean Time Between Failures (MTBF).
• Periodically review EFMEA for critical equipment and systems and ensure timely implementation of identified risk mitigation measures and countermeasures.
• Conduct and review RCFA for major and recurring failures, ensuring effective implementation of corrective and preventive actions to reduce Mean Time to Repair (MTTR) and enhance MTBF.
  
  

4.3 Shutdown Planning and Execution

• Plan, coordinate, and execute shutdown and major maintenance activities efficiently, ensuring minimal impact on production, safety, and furnace stability.
  
  

4.4 Inventory and Spares Management

• Ensure the availability of critical spares and optimize inventory levels through consumption analysis, equipment criticality assessment, and lead-time reviews.
• Initiate timely procurement actions and drive spares standardization and indigenization initiatives wherever feasible.
  
  

4.5 SAP PM and Maintenance Planning

• Ensure effective utilization of the SAP PM module for maintenance planning, work execution, spares management, cost tracking, equipment history, and maintenance performance analysis.
  
  

4.6 Safety, Standards, and Compliance

• Prepare, review, and implement Standard Operating Procedures (SOPs), Standard Maintenance Procedures (SMPs), and Hazard Identification and Risk Assessment (HIRA) documents to ensure standardized, safe, and compliant maintenance practices.
• Ensure 100% compliance with corporate safety standards, statutory requirements, and environmental norms, fostering a zero-incident culture through strict adherence to safe work practices.
  
  

4.7 Coordination and Team Development

• Coordinate closely with Operations, Mechanical Maintenance, Control Room, Projects, and OEM/vendor teams to ensure seamless plant operation and timely resolution of technical issues.
• Lead, guide, and train subordinates and contract manpower to improve technical competency, emergency response capabilities, and adherence to safety and quality standards.
  
  

4.8 Continuous Improvement and Reporting

• Drive continuous improvement initiatives, including Total Quality Management (TQM), 5S, digitalization, and the adoption of advanced monitoring and diagnostic tools.
• Maintain comprehensive documentation and Management Information System (MIS) reports covering equipment performance, deviations, reliability indices, maintenance effectiveness, and improvement actions for management review.
• Technical Skills and Competencies
• Proficiency in electrical drive maintenance and troubleshooting, including Variable Voltage Variable Frequency (VVVF) drives from ABB, Siemens, Yaskawa, and TMEIC.
• Strong knowledge of High-Tension (HT) and Low-Tension (LT) electrical systems, power distribution, electric motors, and associated protection schemes.
• Working knowledge of process instrumentation, including pressure, temperature, flow, and level instruments.
• Knowledge of pneumatic and control valves, actuators, and their applications in process control.
• Experience in the operation, monitoring, troubleshooting, and maintenance of gas analyzers.
• Hands-on experience in preventive, predictive, and breakdown maintenance practices.
• Competence in inventory control, critical spares management, and maintenance material planning.
• Effective utilization of the SAP PM module for maintenance planning, execution, equipment history, and reporting.
• Behavioral Skills and Competencies
• Safety Leadership: Strong safety leadership and discipline, ensuring strict adherence to corporate safety standards and safe work practices.
• Proactive Mindset: Solution-oriented approach with a strong focus on continuous improvement.
• Communication and Coordination: Effective communication and coordination with cross-functional teams.
• Planning and Prioritization: Strong planning, prioritization, and time-management capabilities.
• Accountability and Ownership: High level of accountability and ownership for assigned areas and outcomes.
• Emergency Management: Calm, confident, and decisive approach during breakdowns and emergencies.
• Analytical Thinking: Strong analytical and problem-solving skills under operational constraints.
• Team Leadership: Ability to build, lead, and motivate teams to achieve maintenance, reliability, and safety objectives.
• Qualification and Experience
  
  

CriteriaRequirements

Educational Qualification Diploma / B.E. / B.Tech in Electrical Engineering, Instrumentation Engineering, or Automation Engineering

Relevant Experience More than 5 years of experience in E&I maintenance in process industries

Preferred Industry Experience Blast Furnace / Steel Plant8.2 Downtime Reduction8.3 Equipment Availability8.4 Breakdown Management and Troubleshooting8.5 EFMEA and RCFA Implementation8.6 Maintenance Planning and Shutdown Execution8.7 Inventory and Spares Management8.8 SAP PM Utilization8.9 Safety Performance8.10 Continuous Improvement Practices

• Key Performance Indicators (KPIs)8.1 Equipment Reliability Improvement
• Improvement in MTBF of critical electrical and instrumentation equipment.
• Reduction in recurring equipment failures through effective reliability improvement initiatives.
• Reduction in MTTR through effective troubleshooting, RCFA implementation, and coordination with shift teams.
• Minimization of equipment downtime and production losses.
• Improved availability and uptime of critical electrical and E&I systems supporting production targets.
• Achievement of agreed equipment availability targets.
• Timely and effective resolution of day-to-day breakdowns in coordination with Operations and shift teams.
• Reduction in repeat breakdowns and restoration time.
• Timely review of EFMEA for critical equipment.
• 100% implementation of identified EFMEA countermeasures within agreed timelines.
• Effective closure of RCFA action items to prevent recurrence of failures.
• Accuracy and effectiveness of maintenance planning and scheduling.
• Timely completion of shutdown and major maintenance activities.
• Execution of maintenance activities without compromising safety or furnace stability.
• Availability of critical spares as per equipment criticality requirements.
• Reduction in spares-related maintenance delays.
• Improved inventory turnover through consumption analysis, standardization, and optimized stock levels.
• Effective and consistent utilization of SAP PM for maintenance planning, work execution, equipment history, and reporting.
• Timely and accurate closure of maintenance work orders and recording of equipment failure history.
• 100% compliance with corporate safety standards, SOPs, SMPs, and applicable statutory requirements.
• Achievement of zero safety incidents in the assigned area.
• Timely completion of safety actions and risk mitigation measures.
• Implementation of TQM initiatives and 5S practices in the work area.
• Execution of reliability improvement, digitalization, and maintenance optimization initiatives.
• Measurable improvement in maintenance effectiveness and equipment performance.