Support DMT Mbr Ops 1 (Copper)

1) Job Purpose

Objective of this role is to ensure smooth operation of the plant in the assigned shift by operating the DCS control console to coordinate and regulate process variables and to direct flow rates of various process and utility streams according to prescribed schedules. Coordinate the start-up, shutdown (normal & emergency). Set controls to adjust process variables, such as furnace magnetite, copper loss, matt grade, blister quality, lag chemistry, sulfur in blister, and bearing temperature etc. . This role is also responsible for recording and documenting operating data, and monitoring process indicators.

2) Dimensions:

Business/SBU/Unit Revenue

Business Workforce Number

Permanent workmen – 1750 employees

LMS – 

Management Cadre – 350

Contract labor - 

Unit Workforce Number

Permanent workmen – 1500 employees

LMS – 

Management Cadre – 350

Contract labor - 

Function Workforce Number

Permanent workmen – 550

LMS – 35

Management Cadre – 85

Contract labor - 1000

Department Workforce Number

92

Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter

3) Job Context & Major Challenges:

Job Context: 

• Birla Copper has a copper smelting and refining complex at Dahej producing copper cathodes, cast copper rods, precious metals such as gold silver and selenium, fertilizers, and other bi-products such as sulphuric acid, phosphoric acid etc. in multiple plants with different technologies requiring diverse competencies. There are approximately 1500 employees, across functions at the Dahej unit of which about 350 are in the management cadre. This role is responsible operation of S, CL and C Furnaces, Lance, Feeding system, ASCM, ARM of Copper Smelter 3 supplied by Mitsubishi, achieving targeted production and ensuring preventive maintenance. The key element of this role is maintaining furnace chemistry, monitoring furnace health and controlling copper loss in discarded slag. It involves ensuring optimum liquidation of WIP through C slag, dust and lumpy consumption in S Furnace. The operation involves hazardous processes and generation of corrosive and toxic intermediate products which need to be monitored to be able to keep emissions such as SO2 within permissible limits. The role involves strict compliance of statutory stipulations and compliance of quality, safety, health and environment parameters. It requires continuous process improvement and training.

Job Challenges:

• Smelter 3 is a continuous process that is highly complex in nature requiring 1 Stringent process control at high feed rate (TPH). 2 Rigorous preventive maintenance to eliminate breakdown of the single line equipment and prevent the whole plant from stopping. - Molten metal in launder tend to solidify if not monitored closely, blocking WIP and cash flows - Processes hazardous with corrosive, toxic emissions, minimizing emissions within PCB norms and meeting other environmental and safety norms difficult.

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

Planning

• Giving inputs for Planning shutdowns and routine preventive maintenance to improve uptime of S, CL and C Furnaces

Employee Relation

• Discuss with team members every day to develop better team 

Operational Excellence

Achieving the targeted production of Copper Anodes as per specifications during the assigned shift - Restricting copper losses within norms during the assigned shift - Implementing SOPs and WIs during the assigned shift - Implementing good housekeeping practices and maintaining a clean work environment during the assigned shift

Budgetary Controls

• Implementing optimum utilization of resources is a vis consumption norm to minimize cost of production - Maximizing liquidation of WIP during the assigned shift to ensure minimum blocking of funds and consumable controls 

Compliance

Implementing compliances of Integrated Management Systems, health, safety environment norms

Follow the basic know how’s  and do and don’ts  about  and below safety task force knowledge and know how about all these mentioned below .

Customer-centricity

• Minimizing response time for all internal customers issues

Sustainability and Process Improvement

• Implementing best practice for process improvement - Keeping assets under jurisdiction in good condition - Implementing good housekeeping during assigned shift - Participating in improvement initiatives such as Kaizens, Quality Circles etc. - Implementing good housekeeping practices in area of operation - Partnering in the creation and maintenance of green belt

Contract Labor management

• Ensuring training of S, CL and C Furnace team members to enhance technical and behavioral competencies and increase safety awareness - Implementing 5S and autonomous maintenance culture

People development and engagement

• Monitoring and improving performance of team members - Ensuring training of S, CL and C Furnace team members to enhance technical and behavioral competencies and increase safety awareness - Implementing 5S and autonomous maintenance culture

5) Role Specific  Competencies 

Technical competencies

the knowledge and abilities required to apply specific technical principles and information in a job function or role. Knowledge of equipment- like compressor, bearings, feed tank, dryer, burner, bag filter, dog fan, dumper, belt conveyor etc Material- coal, lime, silica, copper concentrate,

Behavioral competencies

Can assess the impact - understands the value/ implications a change will have on a given function/ process

6)  Job Purpose of Direct Reports:

Position Title

Job Purpose

Position No.

Support operation

Objective of this role is to ensure smooth operation of the plant in the assigned shift by operating the DCS control console to coordinate and regulate process variables and to direct flow rates of various process and utility streams according to prescribed schedules. Coordinate the start-up, shutdown (normal & emergency). Set controls to adjust process variables, such as furnace magnetite, copper loss, matt grade, blister quality, lag chemistry, sulfur in blister, and bearing temperature etc. . This role is also responsible for recording and documenting operating data, and monitoring process indicators.

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