PF-Process

Job Purpose

To support SH Post Clinkerisation in operation and optimization of Cement Mill by daily monitoring & routine inspection of cement mill TPH, power rate loss in cement mills area in field to avoid breakdowns and co-ordination with other department for corrective action of any abnormalities or minimizing downtime of the equipment.

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). 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

Reduction of mills power consumption by improving mills output (rate of cement mills).

Increase percentage of flyash of up to 35%.

Key Result Areas

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

KRA1 Accountability:Production & Quality:

Monitoring Cement Mill optimization

for process operating conditions to

achieve the targeted Production,

Power & Quality as per dispatch

schedule. 1. Maximise the productivity by ensuring smooth and continuous operation of cement mill Ensure quality maintained as per standard

• Monitoring of mill wise power consumption and take corrective action to reduce power consumption.
• Ensure grade wise production as per requirement and correct change over of circuit ensuring product quality.
• Implementation of PM checklist in the section. –
• why-why & PM analysis for process break downs and take corrective measures.
• To monitor calibration of clinker / Gypsum / SSF offly ash weigh feeders.
• Daily Trends review and checklist execution.
• Cross checking of cement blaine whenever it comes abnormal. 9.Planning and monitor smooth changeover of cement grade as per requirement3
• Monitor and ensure timely replacement of grinding media make-up charge.
  
  

KRA2 Cost Control

Process expenses to

operate in budgeted norms and

implementation of improvement

actions for cost optimization. 1.Implement the action suggested to reduce the variance after comparing actual and budgeted cost.

• Use of grinding media within the budgeted norms.
• Evolve schemes resulting in reduction and power cost.
• Monitor false air and idle running of equipment and take corrective action.
• Ensure running of power saving equipment to optimize and reduce power consumption.
• Initiate procurement of grinding media with shutdown planning to optimize idle inventory level.
• making shutdown PRs and MRs.
  
  

KRA3 Modifications And Improvements

Identify areas for improvements,

conduct focussed studies, and

execution of proposals on

modifications /improvements for

Productivity Improvement. 1.Assist in data collection, analysis of data and implement

corrective action based on action plan.

• Analysis of data and feasibility study (Cost benefit analysis) by application of PM analysis.
• Execute action for modification in new proposals.
• Process flow measurement and parameter cross check if found abnormal.
• Identification of source of leakage and ensure corrective action.
  
  

KRA4 4.System Implementation

(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) 1. Execution of counter measures recommended during inter-departmental observation.

• Identify & remove -Abnormalities. -Spillage/leakages
• Execution of Kaizen Schemes.
• Impart training to work man.
• On the job training given to attendant for safe working
• Monitor & ensure effective working of pollution control equipment like ESP, Bag Filters & co-ordinate with service department for optimum operation of the equipment.
• 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 programmes 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.
  
  

KRA5 5.Process Maintenance Jobs

Implementation of various process

maintenance jobs in coordination with other maintenance department to improve equipment availability 1.Grinding media top-up in time.

• Chamber sampling for mill performance with Q.C.
• Grinding media Optimisation.
• separator seal gap inspection, Roller press static gap adjustment and chick plate inspection, Cement ball mill internal diaphragm inspection work
• Check availability of standby equipment by taking no-load trial and timely change over.
• Take maintenance of problematic equipment.
  
  

KRA6 6. 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.