Job Purpose: 

Facilitate the fulfillment of energy requisites for all VSF units and relevant stakeholders in a timely and cost-efficient manner while adhering to statutory regulations and maintaining requisite quality standards.

Dimensions: 

Business Workforce Number   

2500 – 3500

Unit Workforce Number

850

Function Workforce Number

2

Department Workforce Number

17 - 24

• Aditya Birla Group is the Global Leader in Viscose Staple Fibre (VSF). The Pulp and Fibre business of the Group is spread across 7 locations globally. Establishments in India: Nagda (MP), Kharach (Gujrat) and Harihar (Karnataka) and at Vilayat (Gujrat), Purwakarta in Indonesia, Angthong in Thailand, BJFC in China for Fibre units.
• Pulp & Fibre is one of the oldest businesses of the Aditya Birla Group that commenced in1954. Its production units are widely spread across six countries, viz. Canada, Thailand, India, Indonesia, China and Laos. The Central Technical Cell has been created to help and achieve the business vision of being the premium and No.1 quality Fibre producer in the world.  
• The objective of the Central Technical Cell is to provide technical support and persuading with VSF plants towards enhancing competitive edge with respect to environmental, safety and operational efficiencies for producing quality products in line with customer expectations through:
• Promoting Systems based approach based on benchmarking and best practices to operate our plants effectively and drive continual improvement with respect to environment, safety, quality and cost-competitiveness.
• Driving innovation and expertise to spearhead the modification and development of cutting-edge processes in turbines and boilers, ensuring forward-thinking solutions and peak operational efficiency
• Benchmarking within & outside the group for key parameters for all CPPs.
   The Cell is intended to be the one stop shop technical solutions provider to the business units.  The cell will be a repository of knowledge and best practices implemented across the business / industry so as to prevent reinvention of the wheel.

Challenges:

The job calls for monitoring & supporting for all the above-mentioned units and take appropriate action to ensure reliability, optimize steam-power generation & cost of steam-power produced.  The major focus areas of the job are: 

• Boilers are designed for certain intake of specifications of coal, but challenge is to accommodate cheaper available qualities without affecting safety & other parameters as well as firing Alternate Fuels (Agri based).
• Managing the intricate challenges posed by aging equipment, where heightened wear and tear demand a mastery of advanced skills to uphold reliability and optimize efficiencies, ensuring the sustained performance of legacy systems
• Consistently surpassing government-mandated emission norms through proactive measures and innovative strategies, demonstrating an unwavering commitment to environmental stewardship
• Navigating the challenge of water scarcity by implementing resourceful solutions, mitigating non-availability risks, and strategically managing costs amidst escalating prices, ensuring sustainable operations
• Safeguarding optimized power generation by implementing effective mitigations, staying ahead of challenges to maintain peak performance and reliability in the dynamic landscape of power generation
• Pioneering the formulation and implementation of diverse development schemes aimed at enhancing operational efficiency and ensuring cost-effectiveness, driving continuous improvement initiatives for sustainable growth
• Championing the exploration of innovative energy-producing methodologies, with a dedicated focus on minimizing carbon footprints and aligning with a sustainable future.
• Empowering business CPPs by spearheading the establishment of robust Management Information Systems (MIS), identifying operational gaps, and providing strategic solutions to align with their visionary goals.
• Driving CO2 reduction initiatives in harmony with business and group sustainability objectives, ensuring a cohesive approach towards environmental responsibility.
• Guiding CPPs in the development of comprehensive Planning & Budgeting strategies, optimizing resource allocation for sustained operational excellence
• Facilitating the exchange and implementation of Best Practices, both within and outside the ABG, fostering a culture of continuous improvement among CPPs.
• Innovating the development of cost-effective modules to minimize carbon emissions by optimizing the utilization of renewable energy sources, contributing to a greener and more sustainable energy landscape.
• Enabling CPPs in the seamless implementation of Capex schemes, including robust systems for ensuring plant safety and environmental compliance, upholding the highest standards in operational integrity.
• Leading the charge in coordinating, guiding, and supporting VSF plants CPP’s to elevate their competitive edge, focusing on environmental, safety, and operational excellence to consistently deliver high-quality products that not only meet but exceed customer expectations.
• Advocating a systems-based approach, rooted in benchmarking and best practices, to operate plants effectively and foster continual improvement in environmental, safety, quality, and cost-competitiveness.
• Facilitating the modification and development of new processes, ensuring a dynamic and innovative approach to production that aligns with evolving industry standards.
• Spearheading the cross-pollination of existing knowhow between different fiber units, promoting the sharing of expertise to enhance collective capabilities and foster a culture of collaborative innovation.
• Establishing and maintaining a comprehensive repository of knowledge articles, serving as a valuable resource for ongoing learning and informed decision-making across VSF plants.

Key Result Areas: 

1. Power Generation & Reliability Improvement:

Improving Boiler efficiencies, Station Heat Rate & optimization of Auxiliary Power

Ensuring operational excellence through:

• ·         Conducting periodic reviews and ensuring  implementation of corrective actions to uphold the highest standards of performance across units.
• ·         Vigilantly overseeing the operation of Boilers and Turbines, striving to maintain them at optimal efficiency and ensuring timely overhauls in accordance with design values
• ·         Playing a pivotal role in optimizing and debottlenecking Steam and Power Production for VSF Manufacturing and other units, utilizing specialized process and engineering interventions to enhance overall efficiency.
• ·         Leading cost planning efforts and providing coordination and support to units in the implementation of various development activities, ensuring a strategic and cost-effective approach.
• ·         Conducting regular reviews of Unit CPP performance and offering timely corrective and preventive actions to sustain peak operational efficiency.
• ·         Collaborating in the review of customer requirements and providing technical support to all CPP units to meet and exceed these expectations
• ·         Assisting in the identification of root causes behind abnormalities, devising effective solutions, and providing timely feedback to units for swift action.
• ·         Contributing strategic inputs to business and unit leadership to enhance energy generation capabilities with optimized cost and minimal downtime, aligning with the broader goals of sustainable energy management.

2.Cost Control & Optimization:

Plan & monitor the plant operation and maintenance activities to ensure optimum utilization of fuel cost & compliances

• ·         RPO Mitigation for all Indian Fibre Units in most cost effective & sustainable basis 
• ·         Contribute to Optimisation of the Cost of Energy Generation
• ·         Regular Monitoring of operations, Consumption ratios and provide technical support to all CPP Units to achieve their operating efficiency targets 
• ·         Assist in the Identification of process inefficiency due to nonconformance with standard SOPs and provide timely feedback to units for actions. 
• ·         Conceptual formulation, implementation review of developmental schemes to increase the overall plant productivity

3 Performance monitoring of all units: 

Performance monitoring, CAPEX evaluation, support to project teams, sustainability

• Techno Commercial evaluation and viability of Capex proposals from unit to integrate new initiative cost effectively. 
• Evaluation of proposed scheme with respect to layout & process proposed.
• Evaluation of PID & PFD of proposed scheme
• Quotation evaluation w.r.t. time and amount proposed by vendors.
• Evaluation of Bill of material proposed in each scheme by each unit w.r.t. the PID proposed.
• Follow up each UTC, for the proposals in CAPEX sought. 
• Supporting Business cell & COO office for the final presentation of CAPEX to the Chairman’s office
• Evaluation of capex for Annual repairs.
• ·         Responsible for creation/evaluation of developmental proposals from CTC/Units with regards to CPP operation& maintenance
• ·         Mitigations for probable solutions on issues raised by units.
• ·         Supervision of Capex evaluation to ensure that the right technology has been identified for the process proposal 
• Creation of blueprint for brownfield & greenfield projects with regards to CPP & renewable energy generation

4. Waste to wealth & Innovative approach - Fly ash utilization & value added products. Alternate resource to mitigate RPO & minimizing consumption of Fossil fuel

• First, 100 % ash is lifted from all CPPs
   Its quality is maintained as per Cement plant requirement to maximize revenues
• ·         Generating ideas to get value added products from fly ash i.e. Auto Aerated Concrete (AAC), Hybrid Composite Wood, Cenosphere etc.
• ·         While meeting process requirement of HP & LP Steam through CoGen Plant & thus, Producing Equivalent Free Power without using any extra Fossil Fuel & using alternate fuels as per the recent CCTS regulations. 
• ·         To get this free power exempted from RPO through MNRE/CERC/GERC/FEDA & Ministry of Power

5. People Development:

People development, learning of new technologies from market & its implementation in units

• ·         People development
• ·         Develop and sustain an enabling work climate and motivated work force, 
• ·         Identifying training needs and skill Gaps and ensure training is imparted to relevant stakeholders (including at units) with regards to process.
• Interactions / visits with global technology providers.
• Internal & external training
• Attending seminars/workshops.
• Visiting various fares & expo
• Imparting training to Focus 50, mentor for young engineers under TechX

Relationship Type 

Frequency

Nature

Head - CTC

Daily / As & when needed Nature

Interactions, briefing sessions, Opinion gathering & data sharing

Head - CPP

Daily / As & when needed Nature

Interactions, briefing sessions, Opinion gathering & data sharing

Internal CTC Members

Daily / As & when needed Nature

Interactions, briefing sessions, Opinion gathering & data sharing

COO Office

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

Unit heads & UTS Heads

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

Tech. FH

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

DH of Engineering and process department of all units

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

Business Sustainability team

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

Business IT team

Varies from daily to monthly depending upon requirement

Interactions, briefing sessions, Opinion gathering & data sharing

External Consultants, vendors

Depending upon requirement

Consultancy, Opinion gathering