PF Mechanical (ShiftOperation)

UltraTech Cement; Himachal Pradesh; On-site; INR 900,000 - 1,400,000; Full time

Job summary

UltraTech Cement Ltd. is seeking a Plant Maintenance professional to support the SH Mechanical (Pyro) area. The role involves coordinating operations, manpower and equipment to optimise costs and help achieve daily unit targets at the cement plant in Himachal Pradesh.

The role emphasises improving equipment availability, controlling maintenance costs, implementing IMS and safety standards, and driving Kaizen, OPL and continuous improvement initiatives across the section.

Job description

Job Purpose

To support SH Mechanical (Pyro) by handling various operations, manpower and equipment’s effectively to bring cost optimization and achieve daily unit/business targets.

Job Context & Major Challenges

Job Context: UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The company has consolidated capacity of 138.39 Million Tons Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 29 grinding units and 8 bulk terminals.

Baga Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Jaiprakash Associated Limited in the year 2017. Baga Cement Works is located at around 155 Km from Chandigarh, 67 km from Shimla and 37 km from Bilaspur (HP). The nearest National Highway is NH-88 which is 17 Km from the plant. The plant has 10,000 TPD clinker production capacity & 250/300 TPH OPC/PPC cement grinding capacity. The preheater consists of four strings, each with 6 stages of LP cyclones, with two pyroclones supplied by M/s KHD. This is a unique feature of this cement plant due to which the plant operates at lower heat and electrical energy. The preheater has a height of 155 mtrs, with top floor at 135 mtrs. The preheater has been constructed out of tubular steel structure.

The Cement Plant is based on lime stone deposits in Baga – Bhalag hills which are adjacent to plant area. Limestone requirement of the plant is around 15000 TPD. For raw material grinding, two vertical roller mills of 420 TPH each have been installed with a C.F. Silo having a capacity of 24,000 MT.

The unit is equipped with state-of-the-art pollution control systems, and operating emission norms are much lower than the permissible standards of 30 mg/Nm3. Two continuous ambient air quality monitoring stations have been installed which are hooked up to CPCB and PCB and transmit real time data's.

For emergency electrical power, 8 x 1800 KVA, DG sets have been installed.

The township for the plant is located near the plant and has a residential complex for 300 families. 10+2 school and 30 bed hospital has been built. For transporting clinker and cement from plant a fleet of about 4000 trucks have been engaged.ar.

• Space constraints at the unit location.
• Land and possession related disputes regarding ML area falling in different villages is proving to be the bottleneck for scientific development and expansion of mines.

Key Result Areas

KRA1 Accountability – Plant availability

Plan organize and monitor implementation of activities for optimum equipment availability for crushing and feeding. * Monitor equipment availability for running.

• Rectification of minor problems.
• Coordinate/execute improvement actions in the section.
• Coordinate actions to increase Customers satisfaction.
• Avoid idle running
• Cost Control-reduction
• Reduction in section cost by reducing breakdowns.
• Reduction in section cost by avoiding idle running of equipment.

KRA2 Cost Control

Plan, Monitor & Control material, lubricant, Inventory and manpower cost as per budget to optimize maintenance costs * Reduction in section cost by reducing breakdowns.

• Reduction in section cost by avoiding idle running of equipment.
• Avoid over time and optimum utilization of contract manpower
• Control the handling cost by avoiding Spillage.
• Systems

KRA3 System Management

(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) -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.

KRA4 Focus on 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 elevate 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.