Staff Mech ( Shift Operation)

Aditya Birla Group; Aligarh; On-site; INR 700,000 - 1,000,000; Full time

Job summary

UltraTech Cement Limited's Aligarh packing plant seeks an experienced Mechanical Supervisor to plan, organize, and coordinate operations and maintenance activities. The role focuses on manpower planning, spare parts management, and implementing improvements to maximize plant availability and achieve despatch targets while adhering to safety standards.

Key responsibilities include supervising packing plant mechanical work, scheduling shutdowns, analyzing failures, organizing resources, and

Qualifications

• The candidate should have hands-on experience in packing plant operations.
• Experience in maintenance planning and scheduling for cement plants.
• Exposure to condition monitoring and safety practices on large industrial sites.

Responsibilities

• Supervise and coordinate mechanical activities of the packing plant to maximize availability.
• Schedule major shutdowns and routine maintenance activities.
• Analyze breakdowns and implement corrective actions.
• Organize manpower and materials for maintenance work.
• Coordinate condition monitoring of critical equipment.
• Update daily and weekly checklists and reports.
• Monitor equipment availability for production and dispatch.
• Coordinate improvement actions to enhance productivity and reduce costs.
• Ensure safety compliance and drive SHE initiatives.

Skills

Supervise mechanicals

Maintenance planning

Manpower planning

Condition monitoring

Safety compliance

MIS reporting

Tools

Packer machine

Job description

To support Section Head Mechancial by planning, organizing and coordinating operation and maintenance activities, manpower planning, spare parts management and execution of improvement / modification jobs in Packing plant for ensuring maximum plant availability and bringing cost optimization through productivity improvement to meet budgeted despatch targets adhering with UTCL safety standards.

Job Context:- Aligarh Cement Harduaganj (A unit of UltraTech Cement Limited) is located at Village Kasimpur , Tehsil koil Dt. Aligarh (U. P.). It is a grinding & packing unit with an installed capacity of 1.3 MTPA. This unit was commissioned in May -09 consisting of Close Circuit Ball Mill with High Efficiency Separator, 2X12 spout Packer Machine. It manufactures Ultratech Cement in various Blends. This unit is one of our most modern establishments of Grasim Industries Ltd. The basic raw material i.e. clinker received from Vikram Cement, Khor (M.P.) and Aditya Cement, Shambhupura (Rajasthan).
The main product is flyash based, which is being sourced from Thermal power station Aligarh and cement is supplied to mainly in Eastern UP .. The plant has a state of the art technology featuring Expert System of DCS with fully equipped modern laboratory to ensure optimum production and consistent quality product, these are the latest equipment in cement grinding process. 1. To reduce the power consumption. 2. To increase the flyash TPH to design capacity
The focus area for Job holder is to ensure effective Packing Plants operations and maintenance activities and ensuring dispatches as per the requirement of Logistic team.
Major Challenges –
1. Less availability of equipment’s for maintenance due to continuous plant operations and high despatches.
2. To ensure optimum availability of Packing Plant throughout the year and systematic implementation of maintenance schedule to achieve production targets.
3. To optimise operations to achieve better business results in power consumption, fuel consumption and fly ash consumptions.

Key Result Areas

KRA1 Accountability- Supervise & coordinate all the Mechanical activities of packing plant to maximize the plant availability to achieve continuous production as per targets

• Take regular packing plant rounds /study check list daily and identify problems.
• Scheduling of major shutdowns and regular maintenance activities.
• Supervise of maintenance activities.
• Analyze breakdowns and take corrective and preventive actions.
• Organize manpower & material required.
• Coordinate for condition monitoring activities of critical equipment’s.
• Coordinate with other departments for jobs.
• Updating of daily & weekly checklist.
• Monitor equipment availability for running.
• Rectification of minor problems.
• Coordinate/execute improvement actions in the section.
• Coordinate actions to increase Customers satisfaction.

KRA2 Cost Control

• Support SH Mechanical in budget preparation based on past data and future requirements.
• Check consumption pattern equipment-wise with respect to budget and Take corrective actions.
• Arrange manpower requirement in coordination with other section to control overtime & contractor cost.
• Monitor the indents / inventory
• Avoid idle running of packer and equipment’s
• Cost Control-reduction in bag bust age.
• Mechanize / improve handling system of materials.
• Propose changes / modification for attending leakages.
• Reduction in section cost by reducing breakdowns.

KRA3 Management Information System

• Ensuring timely submission of monthly MIS / Presentations and Reports
• Ensuring timely submission of Section Provisions like Budget, Flash Cost, Bills, PR, Service Entries etc.
• Review daily reports and maintains required records regarding operations as requested.
• Ensuring periodic inspection and checking of all lifting tools and tackles.
• Prepare indent & follow-up for material.

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.

KRA5 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 programs 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.