Job Description:

Job Purpose

Assist superior in maintenance activities of HEMM (Heavy Earth Moving Machines), LMV (Light Motor Vehicles), Dozers, Pay loaders, Cranes, Locomotives and mechanical handling equipment of Mines and Plant to improve availability & reliability at optimum cost to meet the production targets.

Job Context & Major Challenges

Job Context: - UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The Company has a consolidated capacity of 137.85 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals.
Maihar Cement Works is a modern cement plant with a high level of automation, computer-aided data acquisition & sophisticated control system, which ensures quality at every stage of production. The Unit is strategically located at Sarlanagar at a distance of about 8 Kms from the town of Maihar on Maihar-Dhanwahi Road in Satna District of Madhya Pradesh. About 45 Kms South-East of Satna, a hub of Cement Industries in India. Maihar is situated at the Main Railway line of Howrah-Mumbai. It is one of the famous dots in the mythological map of India and also regarded as the abode of Goddess Sharda.
The Unit has a clinker production capacity of 3.0 MTPA, Cement Production capacity of 4.2 MTPA & manufactures OPC 43, OPC 53 & PPC grade of cement with Environment clearance for cement production capacity enhancement to 6.0 MTPA. Unit also has a solar power plant of installed capacity 12.5 MW DC / 8.75 MW AC and is equipped with the latest technology & equipment’s. The Normal Power requirement of the Unit is about 47.5 MW which is being met through our two nos. TPP of a total capacity of 2 x 15.7 MW. We have also a contract demand of 22 MVA with MPPKVVCL.
There are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff ColonyThere are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff Colony.
Today, unit is acknowledged as one of the most efficient, vibrant, productive, profitable, technologically updated and state-of-the-art unit of Aditya Birla Group’s UltraTech Cement Business.
This is position is holder is responsible for proper Resource management and maintenance planning, Control of Spares Inventory, Reduction of maintenance cost and Lube oil consumption Improvement in Mines HEMM & LMVs Ensuring Reliability of Mechanical Equipment's.

Major Challenges:
1. Maihar is an old plant with average age of workers is 45 years and many skilled manpower has retireed or is about to retire in next three year. As such this posseses a challenge of availability of skilled manpower in Unit to lookafter Maintenance operations at three locations.
2. Life of equipment is on higher side and upgradation of equipments, while controlling consumptions of spares, lubrication and fuel better than design norms is a challenge
3. Mines maintenance operations are at multiple locations – Mines workshop, Plant workshop and Loco workshop with around 8 kms distance in between which possess a logistic challenge in monitoring and supervising routine operations

Key Result Areas

	KRA (Accountabilities) (Max 1325 Characters)	Supporting Actions (Max 1325 Characters)
KRA1	To save fuel (Diesel) & Lube and consumption of spares and reduce breakdowns of HEMM equipments	Assist Superior to: Monitor preventive maintenance schedule. Random check of maintenance jobs. Liase with stores for spare parts availability. Monitor stock availability of fuel and lubricants Break down analysis and corrective action. Utilisation of SAP/R-3 PM (Module) for history data. Take steps for upgrading of existing equipment. Interact with OEM for major problem & improvement.
KRA2	Cost Control & Optimisation: Assist superior to control maintenance costs of HEMM, LMV, Cranes etc, to optimise cost of operation and maintenance	Assist Superior to: Monitor fuel and lubricant consumption. Standardisation of the equipment to maintain low inventory. Introduction of fuel efficient equipment (engines)Enhance the life of the major sub-assemblies by quality maintenance. Life value analysis. Control contractor & over time cost. Training to operating staff. Identify mechanised maintenance methods.
KRA3	SHE (Safety, Health & Environment) along with Sustainability initiatives	Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area. 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 Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP Active participation in safety training, safety sub committees, standard champions meeting and any safety event Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action Adhering of all safety precautions on the site and off the site Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.
KRA4	System Management (Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)	To implement improvement project to reduce repetitive problems/breakdown or losses. Timely submission of Kaizen, OPL, Good to fine, suggestion on system Developing and sustaining Model area in respective sections 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programmes down the level team To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments. Implementation of critical spares & consumable SOP without any defilement Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.

Qualifications:

Minimum Experience Level:
3-5 Years

Report to:
General Manager