Job Description

Designation: Manager
Updated: November 22, 2024
Location: Gujarat, India
Organization: Pulp and Fibre



:

#### Job Purpose


Plan Monitor and Coordinate the Instrumentation Maintenance Functions of Auxiliary section So as to ensure Optimum Production and delivery with target Cost and Quality.

#### Job Context & Major Challenges


Job Context:

Birla Cellulosic is a situated on the banks of river Kim in the agricultural belt of Hansot- Taluk in Bharuch district of Gujarat. The project was conceptualized in the year 1994 and was fully commissioned in 1998. Brown field project was fully commissioned in 2009. The unit has an installed capacity of 350 TPD of Viscose Staple Fibre and is the most modern Viscose Staple Fibre producing unit of Grasim s pulp & Fibre business. It also has 65 TPD Carbon-DI-Sulphide (CS2), 350 TPD of Sulphuric Acid, 2 x 15 MW, 1 x 10 MW Thermal Power Plant and other auxiliary plants like Water Treatment, Demineralization, & Effluent Treatment Plant etc. Birla Cellulosic has entered into business at a time when globalization is on its peak and quality requirements of the customers are changing very fast. The majority of the management staff is young without specific experience of Viscose Staple Fibre industry and the technicians are first generation industrial workers with agricultural background. The technicians have good financial support. The company has adapted unique HR practices not common to the industrial environment in the area.




Business Context:



Role Context: In this business context, this role plays a critical enabling function in the fibre manufacturing process through the provision of uninterrupted power and steam to the continuous process plants, as per process specifications and ensuring safety in high risk work conditions, while driving cost efficiency.



Main Challenges with us are:




1. Monitor calibration of field instruments and maintained documents as per the calibration planner.

2. Take corrective actions to eliminate deviation observed during calibrations procedures.

3. Monitor preventive maintenance documents as per the preventive planner.

4. Take corrective actions to eliminate deviation observed during preventive procedures.

5. ISO documents preparation for internal and external audits.

6. Co-ordinate with external agencies for Annual maintenance Contract for critical instruments in power plant.

7. Monitoring of online data transfer to higher authority.

8. Timely completion of GCI/GCF scheme related activities without any deviation.

9. To ensure the ageing inventory utilisation.

10. To ensure early replacement of life base critical equipments after getting budget sanctions.

11. To minimize instrument breakdowns by improving uptime of control systems & field instruments.

12. To ensure erection, commissioning, new improvement/Modification, Critical work with understanding interlocks of the system and carryout out with safety.

#### Key Result Areas

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


KRA1 1) Quality



Execution of all preventive Maintenance schedule, timely completion of all schemes with in its stipulated budget & given time frame in Assigned area. 1. Ensure the availability of instrument system to meet the manufacturing targets and other customer requirements

2. Preventive Maintenance Schedule preparation & Evaluation

3. Predictive Maintenance Check list preparation & Evaluation

4. Breakdown maintenance job Execution & guidance to subordinate

5. RCA & Why-Why Analysis to avoid repeated problem

6. Health Monitoring of Instrument through AMS-DCS

7. Shutdown Activity execution & co-ordination with process team

8. Review customer complaints and take relevant corrective action

9. Focus on Reduction in Unplanned Instrument Downtime

10. Upkeep the Automation system to meet manufacturing targets


11. Co-ordinate external agency for scheduling of AMC related work at power plant.


KRA2 Control System maintenance :

To ensure continuous DCS support & trouble shooting 1. Ensure the availability of control system(DCS,PLC,WW Governor) to meet the manufacturing targets and other customer requirements

2. Health monitoring & corrective action to maintain uptime of Controller , I/O cards & operator work station


3. Ensure closed loop controlling by monitoring final control element function & tuning parameter setting

4. Sequence operation troubleshooting to run sequence process smoothly

5. Control system Preventive Maintenance Schedule preparation & Evaluation

6. Ensure PLC system availability by maintaing Grounding & power supply within limit


KRA3 3) DelivModification/Improvement Projects : To suggest the modification / improvement projects to improve quality & productivity in power plant. 1. Ensure product development and plant up gradation to ensure long term liability

2. Introduce technological changes for improved Quality,& Safety with cost effectiveness.

3. MOC preparation /evaluation for change management process


4. DCS logic modification for quality & productivity improvement as per process requirement

5. Provide the services & equipment needed for new products and formulation changes

6. Identify/Evaluation of KAIZEN for implementation

7. Working upon cost estimation & improvement project at EC


KRA4 Spare Parts Management & Cost optimization :

Planning & Monitoring spares management to ensure better cost optimization. 1. Identifying and procuring the required equipment spares and accessories by proper planning and follow up inspecting and accepting the incoming materials with respect to indents raised.

2. Maintaining BOM for Instrument apparatus

3. Procuring required materials by floating enquiries, conducting techno-commercial comparison , dealing with vendors & so on

4. Prepare yearly budgets and Work services to meet targeted requirements and controls.


5. Review budget & Inventory Control by spare material criticality analysis

6. Ensure Maintenance contract are awarded only for special Instrument, rest all activities carried out by utilizing in-house resources

7. Ensure resource management for day to day & shutdown activity


8. Ensure common spare parts management with proper utilization of inventory.


KRA5 People Development:

To enhance knowledge & skills of team/subordinates. 1. Identifying training needs, Skill gap & recommendation for skill improvement

2. Development of maintenance team by structural training & job coaching

3. Train the workforce for safe practices & technical subject for maintain the control system to meet all the environment standard

4. Appraise, Inspires & stimulate subordinate to maximize their performance towards department goals

5. Developing team work culture and safety culture.


KRA6 Safety & Statutory compliance :

To plan the various safety initiates to create safe working condition & also meet the statutory compliances. 1. Critical Instrument Calibration frequency finalize, Schedule preparation & Evaluation

2. Ensure that all Calibration activities are completed within the due date and all the SOPs are "current" and are in use by the concerned person

3. Updating & Maintaining documentation related to projects like user requirement specification, installation, operational & performance qualification

4. Ensure timely review of IMS, WCM, process safety documents to meet the respective standard requirements

5. Review of Policies ,readiness for internal & external audit compliance

6. Identify department HIRA , ASPECT-IMPACT & ensure implementation

7. Six step Safety Observation process follow-up as per schedule

8. Betterment of Instrument System to Ensure Safety

9. Ensure safety practices implementation within team


KRA7 7) People Development



Identifying innovative works and to motivate for more developmental activities.



A Proper guidance and support to technicians.

A Training imparted to increase multi skilling amongst work force.


KRA8 8) System Management

Ensure implementation of QMS/EMS, World Class Manufacturing (WCM) SC & other TPM / TQM initiatives . A Enhance the working of SC in the department improve the monthly score.

A Take corrective steps for effective implementation of WCM sub committee.

A Implement recommendations of audit & close non-compliances.

A Review of proper filling of history sheets and calibration sheets.




Qualifications:

Bachelor Of Engineering


Minimum Experience Level:

10-15 Years



Report to:

Officer