Senior Engineer / Engineer - PF Mechanical (Cement Mill) | RCW

UltraTech Cement; Karnataka; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Rajashree Cement is seeking a Mechanical Maintenance Supervisor for the Cement Mill Line No.1 to supervise and coordinate maintenance activities, maximize plant availability, and drive improvement projects. You will plan weekly shutdowns, supervise maintenance, analyze breakdowns, and coordinate with other departments for timely execution, while focusing on cost control, ISO/EMS/WCM systems, and safety.

This role requires hands-on leadership in 5S, kaizen, and continuous improvement initiatives

Responsibilities

• Supervise & coordinate all Mechanical activities of Cement Mill Line No.1 to maximize plant availability and ensure continuous production.
• Plan weekly major shutdowns and regular maintenance activities; supervise maintenance work and analyze breakdowns; take corrective and preventive actions.
• Coordinate for material indent, availability of manpower, and condition monitoring for critical equipment; update daily/weekly checklists.
• Implement ISO, EMS and World Class Manufacturing practices; drive kaizen, 5S and safety improvements.

Job description

Job Purpose

Supervise & coordinate execution of Mechanical Maintenance activities in Cement Mill of Line No.1 for optimizing plant availability and carryout modification / improvement jobs for cost reduction & productivity improvement

Job Context & Major Challenges

Rajashree Cement is one of the single largest cement plants with an installed capacity to produce 4.2 million tons of cement /annum with captive power plant (58.2 MW) and mines, employing approximately 850 people. It manufactures a range of premium brand of cement and enjoys a reputation of giving value for money. It is one of the largest cement plant at a single location in the country. Rajashree Cement has opted for the Best World Class Technology equipment right from its inception.

The plant consists of 3 Lines, currently producing 2800, 3775 & 4800 tpd as against design of 2200, 3000 & 3500 tpd respectively.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

KRA1 Accountability- Plant Availability

Supervise & coordinate all the Mechanical activities of Cement Mill of Line No.1 to maximize the plant availability to achieve continuous production as per targets * Take plant rounds /study check list daily and identify problems.

• Scheduling of weekly major shutdowns and regular maintenance activities.
• Supervise of maintenance activities.
• Analyze breakdowns
• Take corrective and preventive actions.
• Organize manpower & material required.
• Prepare indent & follow-up for material.
• Coordinate for condition monitoring activities of critical equipments.
• Coordinate with other departments for jobs.
• Updating of daily & weekly checklist.

KRA2 Cost Control

Control cost of all the maintenance activities of Cement Mill of Line-1 as per budget in order to optimize maintenance costs.. * Prepare budget based on past data and future targets.

• Check consumption pattern equipment-wise with respect to budget.
• Take corrective actions.
• Carryout Why-Why analysis.
• Arrange manpower requirement in coordination with other section to control overtime & contractor cost.
• Monitor the indents / inventory
• Mechanize / improve handling system of materials.
• Propose changes / modification for attending leakages.

KRA3 System Implementation

The system requirements of ISO, EMS, WCM systems in cement mill of Line-1 thorough the involvement of employees for improving plant working and quality standard. * Identify and improvement study and kaizen.

• Identify & get rectified.
• Abnormalities.
• Spillage/leakages.
• Unsafe conditions/practices.

5S activities.

• Points emerged in compaigns..
• Implementation plan for
• Quality improvement objectives.
• Improvement of WCM criteria score.
• EMS targets.
• Internal customer rating improvement.
• Statutory compliance.
• Improvement of OEE/MTBF/MTTR
• Elimination of muda.
• Does why why analysis.
• Prepare/present weekly/monthly WCM presentation.
• Develop one point lesson.
• Update WCM activity board
• Create awareness in team members.
• Develop visual controls.

KRA4 Environment & safety

Monitor & carryout all the activities required to maintain good house keeping and safety standards of section.

• Identify spillage /leakage / dust emissions.
• Study problems for corrective actions
• Execute small modifications for improvement.
• Organize timely checking of safety tools tackles & maintain records.
• Educate Workmen / Contract Workmen for safe working practices.
• Analyze accidents, near miss cases.
• Identify potential hazards and unsafe conditions.
• Prepare action plan and implement the same for improvement w.r.t. safety.
• Maintain checklists of pollution control equipments
• . Carryout audit for safety / environment.
• Attend abnormalities identified during audits.

KRA5 Modifications/upgradation

Identify and carryout various modifications/changes required for improvement in plant working on continuous basis in the section. * Analyze breakdowns and suggestions.

• Involve in for elimination of bottlenecks.
• Involve in focussed improvement jobs.
• Attend improvement meetings.