PF-Instrumentation

Job Purpose

Develops, evaluates, implements E&I department's Cement Mill & Packing Plant strategies for continuous improvement, including analyzing equipment needs, reliability issues, developing preventive/predictive maintenance programs and enforce them among maintenance staff also assisting in the design and installation of new systems. Responsible for upgrades to software directly impacting E&I equipment and processes also This includes managing the upkeep of all manufacturing assets, improve productivity at managing/minimum maintenance cost and resources. Ensures a safe, secure, and legal work environment.

Job Context & Major Challenges

Job Context

UltraTech Cement Limited is the cement flagship company of the Aditya Birla Group. A USD 7.9 billion building solutions powerhouse, UltraTech is the largest manufacturer of grey cement, ready mix concrete (RMC) and white cement in India. It is the third largest cement producer in the world, excluding China. UltraTech is the only cement company globally (outside of China) to have 100+ MTPA of cement manufacturing capacity in a single country. The Company's business operations span UAE, Bahrain, Sri Lanka and India.

UltraTech has a consolidated capacity of 138.39 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals. UltraTech has a dealer network of over 30,000 and retailer network of over 84,000 across the country, with a market reach of more than 80% Indian cities and towns. In the white cement segment, UltraTech goes to market under the brand name of Birla White. It has one White Cement unit and three Wall Care putty unit, with a current capacity of 1.98 MTPA. With 230+ Ready Mix Concrete (RMC) plants in 100+ cities, UltraTech is the largest manufacturer of concrete in India. It also has a slew of speciality concretes that meet specific needs of discerning customers. Our Building Products business is an innovation hub that offers an array of scientifically engineered products to cater to new-age constructions.

Narmada Cement - Jafarabad Works was established in 1982 as Narmada Cement Company Limited and merged with UltraTech in 2006. The installed capacity of 1 MMTPA clinker has been gradually increased to 1.50 MTPA (4,300 – 4,500 TPD). Cement capacity is 0.50 MTPA (1,150 TPD).

It is India's first split location dry process cement plant with Fuller technology having four-stage suspension pre-heater, in-line flash calciner, reverse air bag house dust collector, vertical roller mills besides to be the first to unload imported South African coal at plant jetty. It transports 100% clinker to grinding units is in bulk by sea route. The special feature of this plant is Just in Time design for raw mill circuit. As against conventional norms of 20,000 MT silo for raw meal storage it has 2,000 MT silo.

The grinding units associated with Jafrabad Cement Works are Magdalla Cement Works and Ratnagiri Cement Works. All three coast-based split location clinker manufacturing units have jetties. Narmada Cement was the prime supplier of fly ash-based Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada, which is the World's second largest concrete gravity dam (by volume).

Narmada Cement Mine is the captive mine for Jafarabad plant having a production capacity of 2.30 MTPA. It is situated near coastal village of Babarkot, 7 km from Jafarabad port. Out of the total 565.94 hector lease area.

Job Challenges

• Leading section team to resolving instrument, control & electrical technical issues. Assurance maintaining logs and verifying all items are correct prior to pre-inspection. Assisting in developing the annual and multi-year maintenance plan, ensuring that the annual plan is correctly inserted into SAP, Ensuring Section jobs adhere to planned cost and timeline and tracking Via SAP.
• Initiating the participation of the various internal areas/ groups, ensuring that input to the team is timely & adequate and in accordance with the roles & responsibilities. Ensure team is complying with the Preventive inspection report in a timely manner.
  
  

Key Result Areas

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

KRA1 To increase the operational efficiency of the section & reducing unscheduled downtime. (Sustainability) 1. Articulate a plan, review and analyze preventive maintenance plan for the equipment in order to achieve highest efficiency of the activities for reliable and safe operation.

• Deliver technical services during troubleshooting and corrective action of instrument breakdown or failures to find the root cause and best solution in order to restore the functionality back to normal within least possible time.
  
  

KRA2 Cost Optimization 1. Forecast and prepare budget for related activities i.e. maintenance, shutdown and project for consolidation into department yearly Work Program and Budget. Monitor budget utilization closely and provide justification for variance.

• Monitor spare parts and inventory for critical instrumentation to ensure availability when required in order to minimize production interruption. Establish new inventory/cataloging where necessary. Update information in the inventory to ensure it is relevant for the current operation.
  
  

KRA3 System Implementation and People Development 1. Supervise and groom FLE's to develop his technical knowledge, Safety level, skills and Behavioural competencies in order to produce potential talent for future business needs.

• Maintains ABOE and other UTCL Systems by establishing, following, and enforcing standards and procedures; complying with codes and legal regulations.
  
  

KRA4 Safety & statutory compliance 1. Carryout timely inspection of all jobs required as per Electrical Inspectorate/ statutory guidelines and ensure their timely compliance.

• Carryout the required checking, testing as per guidelines. Maintain statutory records of the observations.
• Take corrective measures for deviations. Monitor working of line clearance system. Identify & rectify unsafe points & unsafe practice in the area.