Executive / Sr. Executive- Operations (Productions)- Nanhwara

Walplast Products; Katni; On-site; INR 600,000 - 1,000,000; Full time

Job summary

Walplast Products in Madhya Pradesh (Katni) seeks a Production/Plant Operator with 4–6 years of experience in gypsum processing to lead grinding and calcination operations. You will plan daily production, monitor equipment, ensure product quality and optimize energy use while coordinating across sections and maintenance teams.

The role emphasizes ownership, accountability and problem-solving in a busy gypsum plant environment.

Qualifications

• Diploma or BE in Mechanical Engineering.
• 4–6 years of relevant experience in gypsum/cement production.
• Ownership, accountability, learning agility and problem-solving.

Responsibilities

• Execute daily production plan for Grinding and Calcination per production requirement.
• Ensure achievement of daily, shift-wise and monthly production targets.
• Plan raw gypsum feeding, grinding and calcination according to silo levels and downstream requirements.
• Coordinate with Dispatch, Packing and other production sections to maintain continuous plant operation.
• Operate and monitor Grinding section equipment (Crusher, 4-Roller/6-Roller Mill, Conveyors, Elevators, Valves, Feeding systems, Blowers, Dust collection).
• Maintain mill feed rate, grinding capacity, product fineness and monitor vibration, pressure and motor load.
• Ensure stable feeding to calcination section and avoid mill choking or overloading.
• Optimize mill operation to reduce specific power consumption; coordinate with Maintenance for issues.
• Operate and monitor Calcination section (Vertical Calciner/Kettle, Boiler/TFH, Coal Feeding, ID Fan).
• Maintain calcination temperature and residence time; monitor coal consumption, air flow and boiler parameters.
• Manage process control to keep parameters within range; identify trends and optimize energy and process efficiency.
• Coordinate quality control with Lab for fineness, setting time, moisture and density; ensure traceability.
• Oversee equipment and process reliability; coordinate with Maintenance during breakdowns and maintenance.
• Monitor coal consumption daily and reconcile with production; implement coal reduction initiatives.
• Manage silo and material handling to avoid overflow and optimize transfers.
• Supervise shift operations, ensure handovers, produce shift reports and enforce SOPs.

Education

Diploma/ BE (Mechanical)

Job description

Role & responsibilities

1. Production Planning & Target Achievement

• Execute daily production plan for Grinding and Calcination as per production requirement.
• Ensure achievement of daily, shift-wise and monthly production targets.
• Plan raw gypsum feeding, grinding and calcination according to silo levels and downstream requirements.
• Coordinate with Dispatch, Packing and other production sections to maintain continuous plant operation.

2. Grinding Section

Responsible for operation and monitoring of:

• Crusher
• 4-Roller Mill / 6-Roller Mill
• Screw Conveyors
• Bucket Elevators
• Rotary Valves
• Feeding Systems
• Blowers
• Dust Collection Systems

Key responsibilities:

• Maintain required mill feed rate and grinding capacity.
• Monitor gypsum feed size and ensure proper grinding.
• Maintain required product fineness.
• Monitor mill vibration, differential pressure, motor load and other operating parameters.
• Ensure stable feeding to the calcination section.
• Avoid mill choking, overloading and empty running.
• Optimize mill operation to reduce specific power consumption.
• Coordinate with Maintenance for abnormalities and breakdowns.

3. Calcination Section

Responsible for operation and monitoring of:

• Vertical Calciner / Kettle
• Boiler / TFH
• Coal Feeding System
• ID Fan / Blower
• Rotary Valves
• Screw Conveyors
• Calcined Gypsum Silos
• Associated temperature, pressure and instrumentation systems

Key responsibilities:

• Maintain required calcination temperature and residence time.
• Ensure stable and continuous feeding of gypsum to the calciner.
• Monitor:
• Feed rate
• Calcination temperature
• Material temperature
• Coal consumption
• Airflow
• Draft/pressure
• Boiler/TFH parameters
• Product quality
• Ensure proper calcination and avoid under-calcination or over-calcination.
• Maintain required coal consumption per MT of stucco.
• Optimize fuel and air ratio for efficient operation.
• Monitor calcined gypsum quality and take corrective action whenever parameters deviate.

4. Process Control & Optimization

• Maintain process parameters within the defined operating range.
• Identify abnormal trends before they result in production loss or quality problems.
• Optimize mill capacity, calcination rate and fuel consumption.
• Monitor specific power consumption and coal consumption per MT.
• Identify opportunities for energy and process optimization.
• Maintain operating standards and SOPs.

5. Quality Control

• Ensure required gypsum/stucco quality as per specification.
• Coordinate with the Quality/Lab team for:
• Fineness
• Setting time
• Free moisture
• Combined water
• Bulk density
• Other applicable quality parameters
• Take immediate corrective action in case of quality deviation.
• Maintain traceability between raw material, process parameters and finished product.

6. Equipment & Process Reliability

• Carry out routine inspection of operating equipment.
• Identify abnormal sound, vibration, temperature, leakage, belt/chain condition, etc.
• Immediately inform Maintenance about equipment abnormalities.
• Coordinate with Maintenance during breakdowns and planned maintenance.
• Ensure equipment is handed over safely for maintenance and properly taken back after completion.
• Minimize production loss due to operational issues.

7. Coal Consumption Monitoring

• Monitor daily coal consumption and calculate kg coal/MT of stucco.
• Reconcile coal feeding with production.
• Identify abnormal/excessive coal consumption.
• Maintain daily coal consumption records.
• Work on initiatives for coal reduction and heat recovery.
• Support implementation of coal weighment and automated feeding systems.

8. Silo & Material Management

• Maintain optimum levels of:
• Raw gypsum silo
• Ground gypsum silo
• Calcined gypsum/stucco silo
• Avoid silo overflow and low-level situations.
• Coordinate grinding and calcination operation based on silo availability.
• Ensure proper material transfer and avoid unnecessary material handling losses.

9. Shift Management

• Supervise operators and helpers working in Grinding and Calcination.
• Allocate manpower effectively.
• Ensure proper shift handover.
• Maintain shift production and process reports.
• Ensure operators follow SOPs, checklists and operating instructions.
• Monitor operator discipline and performance.

10. Safety

• Ensure safe operation of Grinding and Calcination equipment.
• Ensure PPE compliance.
• Follow LOTO requirements during maintenance.
• Ensure safe handling of hot material, coal and rotating equipment.
• Report unsafe conditions immediately.
• Ensure compliance with plant safety procedures and emergency protocols.

11. Reporting & Documentation Maintain:

• Shift production report
• Grinding production and operating parameters
• Calcination production report
• Coal consumption report
• Specific power consumption
• Equipment running hours
• Breakdown/production-loss details
• Silo stock levels
• Quality results
• Shift handover report

Preferred candidate profile

Education - Diploma/ BE (Mechanical)
Experience - 4-6 years of relevant experience
Product knowledge- Gypsum / Cement
Behavioural Competencies - Ownership & Accountability, Learning Agility, Problem Solving