1) Job Purpose:

To ensure the normal operation of theplant on continual basis and identify deviations in performance (Quality, Quantity, Safety and consumption of materials) from set standards.

3) Job Context & Major Challenges:

Job Context: BUSINESS: PULP AND FIBRE The production of Viscose Staple Fibre (VSF) was first started in 1954 with a small capacity of 5 KTPA at Nagda (India). Today, VSF is a core

3) Job Context & Major Challenges:

business for Aditya Birla Group. It presently enjoys 23% global market share with production of 566 KTPA. The Group s VSF business operates through its three companies Grasim (India), Thai Rayon (Thailand) and Indo Bharat Rayon (Indonesia) which also oversees operations at Birla Jingwei Fibres, China. The group has also concurrently expanded its presence in Dissolving grade Pulp production to support the raw material requirement of its VSF operations. The group has two Pulp Plants in Canada and one in India. It has initiated a Pulp and Plantation project in Laos to strengthen its backward integration. PT. INDO BHARAT RAYON: Established in 1980, PT. Indo-Bharat Rayon (IBR) pioneered the production of VSF in Indonesia. The Company s plant situated at Purwakarta in West Java, commenced commercial production in 1982 with a modest capacity of 16,500 TPA and through strategic investments in expansions over the years, today has an installed capacity of over 155,000 TPA and has become one of the world s largest manufacturers of VSF at a single location. Marketed under the brand name of `Birla Cellulose . The Company produces a wide range of VSF in engineered specifications for textiles and non-woven applications. Today, IBR not only has a dominant share of the domestic market but also caters to customers in USA, Europe, Turkey, Korea, Japan, South Korea, China, Morocco, Philippines etc. The Company also produces chemicals like Anhydrous Sodium Sulphate and Sulphuric Acid. Anhydrous Sodium Sulphate is widely used in detergent, textile dyeing, glass, pulp and paper industries. IBR has a Captive Power Plant which makes it self reliant for its requirement of steam and power. Pulp & Fibre Business in AB group has a vision of achieving 40% world market share by year 2010. IBR is expected to become largest plant with highest production capacity at single location. In Indonesia, the pollution control norms are becoming more & more stringent and lately there is increasing focus on abatement of air pollution and solid waste management. In the era of stiff competition continuous focus on cost drivers to improve the efficiencies has been the key to improve business results

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

Reliability improvement of plant equipments and assets  

Accountable for  

1) ensuring   reliability improvement of all plant equipment and assets of main plant     , ancillary plants and  ETP

 2) Ensuring     trouble free running of plant equipment to its best performance levels

 3) Ensure repair / replacement of assets / equipment in time to time to enhance   health of the equipment and assets 

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1. planning short-term and long terms plan for various maintenance activities to ensure reliable running of equipments 
2. Review and Monitor the plans periodically to ensure implementation in time and to support the team to complete the tasks
3. Review, monitor the implementation of suggestions & recommendations of the  root cause analysis of the equipment downtimes so also  eliminate the failure  causes .
4. Review and monitor the deptt procedures and daily management systems so as to ensure the systematic working within the deptt 
5. Identify and review short / medium / long term improvement plans for old / deteriorated equipments and assets  and recommend new projects / schemes.  
6. Review the planned maintenance plan and implementation of the activities in planned stoppage so as to ensure that the jobs are completed within time with quality  and safety
7. Ensure to attend the break down jobs  as fast as possible so as to ensure minimum down time 
8. Periodical review of the spare parts planning  so as to ensure the spares availability  all time 
   1. Encourage the team to adopt new maintenance and inspection methods to  improve diagnosis of the defects systematically , and to improve the maintenance  

 Assets and equipment integrity in the plant premises:

  Accountable for 

1)Ensuring the integrity of assets and equipments 

2)Ensuring the statutory  / legal compliance  of the assets  and equipments 

1. plan , Monitor, review and strengthen  condition monitoring activities for predictive maintenance of plant equipment and assets
   1. Develop, implement and review mechanical integrity inspection plan and quality assurance plan   for plant equipment’s (both rotating and static)
   2.  Ensure periodic third party inspection  to measure     the  integrity of the plant buildings and structures and implement the recommendations 
   3. Ensure to carry out  and implement all kind of statutory inspections 
      1. Encourage the team to adopt new condition monitoring practices for better and consistent results 

Safety and Environment  compliance 

 Accountable for   compliance of safety & environments norms to maintain safe & healthy working environment in the plant.

1. Ensuring the jobs are carried out by adopting all safety standard practices by conducting periodic audits / inspections at field
2. Periodic review of the SOP /SMPs / permits etc to ensure that all the safety and environment norms are met 
3. Conducting BBSO and Field audits to  find out gaps and to ensure elimination of unsafe practices and conditions  
4. Review the Safety action plan of the each  team member     to ensure proper adherence of them to safe working practices 
5. Monitor and review to ensure compliance of  all safety / legal inspections of tools and tackles / pressure vessels/ safety critical equipments etc 

Implementation of all management systems

Accountable for implementation of all management systems    without any deviations 

1. Developing / reviewing systems for proper implementation of management systems
2. Monitor and review with team members to ensure that the systems are well understood and properly implemented
3.  Periodically review the     records to ensure the compliance 
4. Setting of stretched targets in terms of KRA in line with Units target of all engineering / maintenance functions and distribute them to all individual for their responsible
5. Review the KRAs periodically to review and guide the team for achieving the targets 
6. Conduct deptt meetings to review the progress in the deptt functioning 

Implementation of Cost control, and inventory management 

Accountable for 

1. carrying out the activities in the engineering function within the allotted budget by controlling the expenses without compromising the quality and safety of  jobs
2. Inventory management 

1. Monitor and  review of the expenses incurred by each section and implement the cost control measures
2. Monitor and review of the inventory level and implement inventory control measures
3. Encourage import substitution of the spare parts to reduce the purchase cost
4. Periodical review with purchase team to optimise the purchase volume of the high value spares 
5. Review the stock level of spare parts and optimise the spare parts procurement
6. Developing good quality vendors to ensure quality of spares 

 People Development            

Accountable for 

 1) development of the subordinates  

2) skill development of the team 

3) ensuring various  training to the team members for their overall development 

 4) Grievance addressal of the team members 

5) Optimum utilisation of manpower 

1. Periodical review of the skill level of team members to asses the skill levels and act for development 
2. Periodical review of the training  programs attended by team members for the relevant skill development .
3. Job rotation of the people to ensure the skill development 
4. Give additional responsibility to the people for their confidence building and skill development 
5. Encourage reward systems to the people in time for the remarkable jobs done by them
   1. Frequent interaction with HR team for people development and grievance addressal 

5) Job Purpose of Direct Reports:

Position Title

Job Purpose

DH Civil

Plan, Direct, organize, co-ordinate & monitor implementation of Civil construction and maintenance activities of IBR & provide technical support for Indo Raya Kimia for projects, Capex initiatives and existing installations for plant and non plant buildings, roads, establishment and facilities to ensure that the new initiatives are completed in budgeted cost and time frame and the infrastructure is well maintained in line with the company plans and objectives.

DH Mechanical

Plan, direct and monitor maintenance, modification, and expansion activities of Spinning Department including Painting and Insulation of whole VSF Plant and Plan and organize workshop and Central Maintenance activities to support complete VSF Plant to ensure quality and quantity of fibre production as per agreed norm within targeted cost

Advisor Mechanical

Plan, implement, monitor and guide viscose production, maintenance and expansion activities to achieve volume, quality, efficiency and cost as envisaged in annual and expansion budget and ensuring availability of viscose with desired process parameters for producing quality fibres as per customer needs. Plan, direct, and coordinate Acid Plant activities related to operational management and development so as to meet agreed organizational performance plans within agreed budgets and time scales (covering all relevant areas of operation e.g manufacturing, maintenance, distribution and product quality) meeting all safety & environmental compliances.

DH Instrumentation

 To    plan,    manage,    coordinate    &    control    all    the

Instrumentation activities of Main Plant ( existing lines # 1 & 2 and expansion of Line # 3 & 4), CS2 ,Acid, WTP, ETP Plants, Telecommunication activities of plant & colony, & cable network. To minimise the down time due to the breakdown of Instruments & the Control Systems and ensure prompt, defect free & reliable service of all the instrumentation & telecommunication systems, within the budgeted cost & in order to facilitate the plant operation to achieve targeted production & quality standards.

DH Electrical

Plan, monitor and coordinate the Electrical activities of VSF Plant and to develop technical skills of down line Engineers/workforce for new Technologies, so as to ensure optimum production and delivery within targeted cost and quality parameter.