Job Description

:Job PurposeTo support SH E&I in ensuring maximum plant availability & improving productivity at optimum cost by supervising and coordinating safe operation and maintenance activities of Instrumentation softwares and equipments and eliminating problems by gathering requirements and implementing process automation.Job Context & Major ChallengesJob Context:- Ultratech Cement Limited Unit : Aligarh Cement Works 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 \xe5\xa4\x9a09 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 Ultratech Cement Ltd.
The basic raw material i.e. clinker received from Vikram Cement, Khor (M.P.) and Aditya Cement, Shambhupura (Rajasthan). The main product is fly ash based, which is being sourced from Thermal power station Aligarh, Kasimpur . 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..
Today, unit is acknowledged as one of the most efficient, vibrant, productive, profitable, technologically updated and state-of-the-art unit of Aditya Birla Groups UltraTech Cement Business.
The focus area for Job holder is to ensure operation and maintenance activities of Instrumentation equipments in plant and colony and also for providing timely and accurate information to Management for taking strategic decisions.
Major Challenges -
1. 24*7 accurate availability of environment data to CPCB.
2. Availability of DCS data to maximum users through PI for optimum utilisation of process parameters and formation of reports etc.
3. To Manage all E&I Activities with revised manpower requires a need to build capabilities of team to handle both roles. Skill development of workmen for smooth plant operation.
4. Less availability of equipments for maintenance due to high dispatches and fluctuating demands effects the equipment efficiency.Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)
KRA1 Plant Availability
Timely Completion & implementation
of maintenance activities for
maximum availability Instrumentation section for achieving
targets with respect to downtime,
maintenance work and customer
satisfaction. 1. Troubleshooting of Inst. Related problems in time for achieving the plant availability.
3. Follow maintenance plans.
4. Timely Completion of PM schedule.
5. Timely Completion of jobs in shutdown.
6. Review breakdowns & carryout analysis for problems.
7. Take corrective actions.
8. Installation, testing and calibration of all field instrument
9. Installation, commissioning, testing and calibration of weighing systems
10. Erection of IO panels, Optical fiber and Profi bus cable laying
11. Carryout why-why analysis, review drawings / specifications.
12. Analyses the frequent problems, tripping, breakdowns.
13. Identify areas requiring improvements.
14. Taking plant round, supervise maintenance jobs, coordinate with other dept. / Sections for plant performance improvement job.
KRA2 Cost Optimization 1. Prepare budget for E&I related activities i.e. maintenance, shutdown and project for consolidation into sections yearly Work Program and Budget.
2. Monitor budget utilization closely and provide justification for variance.
3. Plan, monitor and control cost (spares, Inventory) of Instrumentation maintenance activities P to optimize maintenance cost within the budget.
4. Inventory Review & Maintain Critical Spares
5. Reduce consumption by improving uptime of plant.
6. Controlling Overtime
KRA3 Data Security and Process Optimization. 1. Data security and configuration backups of all servers so that IT security compliance of our group are not violated.
2. Software upgradation and antivirus updates of all Servers, clients, engineering stations and firewalls.
3. Optimization of software loops for cost reduction and easy process operation.
4. Availability of plant data to maximum users through PI for easy process utilization.
KRA4 Continuous Improvement:
Study and identify projects,
coordinate and monitor
implementation of up-gradation/
modification/de-bottle necking/
improvement projects to improve the availability & reduce cost of Electrical & Instrumentation maintenance. 1. Collection of data on failures and bottlenecks & identification of improvements projects.
2. Analysis of failures.
3. Identify improvement actions.
4. Formulate proposal i.e., equipment specification, drawings etc.
KRA5 Shutdown Jobs Performing 1. Prepare the job list for shutdown as per priority for the plant.
2. Proper Job planning for shutdown jobs.
3. Planning of contractor jobs to be carried out and raise service work order accordingly.
4. Spare parts planning for major shutdown jobs as well as fulfilling day today basis requirements.
5. Planning and procurement of advanced good quality tools and tackles for fast execution of jobs
KRA6 Management Information System 1. Ensuring timely submission of monthly MIS
2. Ensuring timely submission of Section Provisions like Flash Cost, Bills, PR etc.
3. Timely and accurate preparation of Presentations, Reports etc. as required by Management from time to time
4. Supporting and handling various internal and external audits.
KRA7 System Management
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) 1. To implement improvement project to reduce repetitive problems/breakdown or losses.
2. Timely submission of Kaizen, OPL, Good to fine, suggestion on system
3. Developing and sustaining Model area in respective sections
4. 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
5. To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
6. Implementation of critical spares & consumable SOP without any defilement
7. Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.
KRA8 Focus on SHE (Safety, Health & Environment) along with Sustainability initiatives 1. Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.
2. Educating team about I know my job, I know the hazards associated with my job and I applied control measures & I escalate to my senior among manpower deployed in sections/department manpower including peer, WB & CL manpower
3. Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
4. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
5. Active participation in safety training, safety sub committees, standard champions meeting and any safety event
6. Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
7. Adhering of all safety precautions on the site and off the site
8. Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

Aditya Birla Group