PF R&D (Physical Testing)

Job Purpose

To carryout physical analysis of market cement samples and to highlight deviations for improvement projects. To assess & evaluate lab practices of all UTCL Units as part of lab proficiency testing and impart training to gaugers, for ensuring conformance to standards.

Job Context & Major Challenges

Job Context:

UltraTech Cement is the largest Cement Manufacturer of the country. Its Grey Cement Business have 12 Integrated cement manufacturing Units, 14 Grinding Units and 6 Bulk Terminals at present (2015). 2 GUs are under construction. 2 IUs and I GU are being planned.

Growth of Indian Cement Industry is forecasted from present 282 mtpa capacity to 550 mtpa by 2020. In order to at least maintain market share, UltraTech will go from 64.7 mtpa to more than 100 mtpa during the same period.

To maintain the leadership position of UltraTech in India and to achieve ambitious growth enabling to be prominent global player, warrants meeting vital need for technical expertise of high order.

Even in commodity industries, competition is getting knowledge driven. Scale, size and cost driven strategy will no longer be sustainable. Customer centric Innovation has already started playing a key role for sustainable competitive advantage. The need is therefore innovation driven differentiation and Know How driven cost optimization. With sudden changes in technology, digitization and analytics would be new drivers of operational excellence.

Further, the group aspires to be most efficient cement business in the world in all spheres of business encompassing product, quality, cost, safety, environment, etc. Considering the magnitude of operations and challenges involved, R&D is expected to play a pivotal role in terms of value addition and problem solving in all the facets of challenges.

The Go-To Experts and Specialists at C R & D would provide action plans and facilitate, monitor and ensure implementation of action plans for improvements and enhancements of plant performance across the Grey Cement Business and contribute to and ensure achievements Business results

Major challenges

• Physical analysis of large number of our and competitors market cement samples with accuracy and on time is a difficult task. It requires meticulous working and monitoring.
• It is essential to maintain accuracy & reliability of physical analysis. Therefore, task warrants high proficiency in testing & analysis.
• The job holder has to continuously survey and study relevant upcoming standards. Job holder should be tactful during lab proficiency assessment and able to impart knowledge, and influence for getting buy in of the corrections from lab personnel.
  
  

Key Result Areas

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

Kra1 Kra:

Market Cement Analysis

Accountability:

To execute plan for physical analysis and evaluation of cement samples from the market across geographies and highlight deviations.

KPIs:

• Testing of planned cement samples. Actual Vs. Planned. Target 100%. UOM: Number / %.
• Time frame for testing &draft report. Actual Vs. Target. UOM: Number of days.
• Discrepancies, identified by superior in the test results. Actual Vs. Target Zero. UOM: Number.
• Accuracy and comprehensiveness of analysis report in terms of errors and revision by superiorrespectively. Actual Vs. Target, Zero UOM: Number of errors/revisions 1. To receive and check cement samples of UTCL and competitors across geographies, received from TASC.
• To conduct physical analysis (Blaine Surface m2/kg, Normal consistency, Setting times, Autoclave & Le-Chatlier expansion, Compressive strengths, residue at 45 µm, Particle size analysis, etc.) and evaluation of market cement samples as per plan.
• To develop & update SOPs for analysis and adhere / ensure adherence to SOPs.
• To timely completethe testing as per scheduled plan.
• To study test results, identify deviations, and repeat the testing / analysis.
• To prepare& submit a draft report to superior for review.
  
  

KRA2 Assessment& Evaluation of QC Labs

Accountability:

To assess practices of physical analysis and upkeep of all equipments of QC labs across the Business during lab proficiency testing, enabling corrections in practices, reliability of physical analysis & consistency of results.

KPIs:

• Number of Units covered under the assessment/ratingprogram: Actual Vs. Scheduled, UOM: Number.
• Unit wise time frame for proficiency evaluation program. Actual Vs. Target. UOM: Number of days.
• Proficiency evaluation accuracy in terms of errors. Actual Vs. Target zero. UOM: Number of errors. 1. To adhere to the plan for proficiency testing of QC lab of all Units.
• To carry out systematic inspection of procedures and practices of QC labs across plants.
• To examine the proficiency of the physical lab through analysis of standard cement samples and also the ongoing plant sample.
• To assess adherence of lab practices to relevant Indian Standards.
• To identify discrepancies in procedures / practices.
• To prepare report of findings for review.
• In case of discrepancies, advise corrective measures by plant QC.
• To keep updated with forth coming Indian & International standards, conduct analysis with new standards, resolve issues if any and put them into practice.
  
  

Kra3 Kra:

Technical training

Accountability 3:

To compile technical training needs of employees and ensure fulfilling the needs making them technically competent.

KPIs

• Trainings & Workshops organized for meeting the objectives. Actual Vs. Target. UOM: Number.
• Effectiveness of training in terms of number of participants showing improvement in test scores. Actual Vs. Target 100 %. UOM: Number, %. 1. Based on the action plan furnished by superior for technical training of employees, schedule training programs.
• To prepare study materials, course materials, test materials for the program.
• To conduct and deliver the program by using different training methodologies – class room, demo, pre & post program tests, practical, doubt Q & A sessions.
• To collect feedback from participants about the training program.
• To revisit program contents, methodology, testing based on feedback.
• To collect feedback from participants superiors about implementation of learnings on the job and take required action
  
  

Kra4 Kra:

Calibration of Physical Lab equipments

Accountability 4:

To carry out calibration of all Physical lab equipments in Khor enabling upkeep.

KPIs:

• Coverage of machines for calibration. Actual Vs. Target100% machines. UOM: Number, %.
• Delayin Calibration Of equipments. Actual Vs. Target, Zero. UOM: Number of days.
• Calibration accuracy in terms of errors. Actual Vs. Target zero. UOM: Number of errors. 1. To meticulously execute the plan & schedule of calibration exercise.
• To carry out periodic systematic calibration of physical laboratory instruments of C R & D labs in Khor.
• To strictly adhere to the scheduled plan for timely completion of calibration.
• To adhere / ensure adherence to the SOPs.
• To identify discrepancies in calibration.
• To prepare report of findings.
• To issue calibration certificate when calibration test is passed.
• In case of failure in calibration test / discrepancies, advise corrective measures.
• Repeat calibration after corrective measures. Issue certificate when calibration test passed.
• To prepare schedule, coordinate with purchase for issue of work order and ensure execution on time
  
  

KRA5 Periodic evaluation of marketing cement samples Conducting the experiments

Calibration of all physical and chemical testing

Periodically calibrate and standardize the equipments like Blaine apparatus, automatic compressive testing machine, calorimeter, electronic balance, vibrating machine etc.

KRA6 System Implementation

Implementation of VMS system as per guideline * Sample collection and kept properly

• Representative sample preparation by coning and quartering method.
• Conducting the all physical properties
• Conducting chemical properties like LOI insoluble residue & SO3 content.
• Data entry in computer and plotting the graphs.
• Results compilation and correlation.
  
  

Results reported to Senior / HOD.

• Conducting the required experiments.
• Following the procedures as per BIS, ASTM & EN.
• Maintenance of equipments.
• Zero breakdown.
• Reliable and authentic results produced.
• Maintain the records.
  
  

KRA7 1. Preparation of records as per system requirement.

• Assist in the preparation of WCM board