Follow the instructions of instrumentation installation & project activities in VAPs plant to ensure and maximize the plant availability within the budgeted cost and time and ensuring quality, safety, environment and good maintenance practices to meet the desired level of productions.
Chemicals Business of Aditya Birla Group produces Chlor-Alkali products among other Chemicals through seven units situated in different parts of the country. This is the Eighth unit which is under project phase. ABG is largest producer of Chlor Alkali in India with a market share of approx.30%.
One of its state-of-the-art manufacturing facilities is based at BBPURAM having the capacity to produce 400 TPD of Caustic. The Unit also produces Chlorine derivate namely Chlorinated Paraffin’s (CP, Stable Bleaching Powder (SBP) & Monochloro Acetic Acid (MCA).
The unit, located in the East Godavari Dist. of AP state, is poised for an ambitious growth.
Major Challenges :
1.Accuracy and Calibration
2.Environmental Conditions
3.Integration and Compatibility
4.Troubleshooting and Diagnostics
5.Safety and Hazardous Areas
6.Reliability and Maintenance
7.Technological Advancements
8.Interdisciplinary Collaboration
| KRA (Accountabilities) (Max 1325 Characters) | Supporting Actions (Max 1325 Characters) | |
|---|---|---|
| KRA1 | Plant Maintenance: Organize & co-ordinate execution of Instrumentation maintenance activities | •Organize and review daily maintenance activities in the concerned areas so that the schedules are followed strictly and quality & timely completion is ensured •Check preventive maintenance, shutdown and predictive maintenance systems for abnormalities and take corrective action for elimination •Check breakdown failures, shutdown losses, maintenance expenditure, repair time, manpower cost, overtime every month and identify activities for improvement •Refer Chronic problems to superiors and concerned for advice and remedial measures •Monitoring OEE, MTBF & MTTR, gap identification and preparing action plan for improvement •Supervise resources during breakdowns, shutdowns & planned maintenance •Coordinate with purchase, stores & P&A to organize necessary resources like material & manpower for uninterrupted & timely completion of maintenance jobs •To ensure the availability of critical spares after identification by ABC analysis established in designated areas |
| KRA2 | Plant Maintenance: Organize & co-ordinate execution of Instrumentation maintenance activities | •Manage shift activities and ensure availability of maintenance resources in all shifts •Timely communicate all requirement and issues to the Department Head and garner support and guidance •To ensure and implement safe working culture in the department by tool box talk, on job trainings etc. •To ensure & monitor calibration reports, material reservation, purchase requisitions and service entry through SAP for MIS to appraise management to take informed decision. •Ensure that SAP activities of material reservation, reports, service, entry etc are carried out departmentally for smooth procurement process. |
| KRA3 | Planning & Budgeting, Cost Control and improvements Check for Instrumentation maintenance expenditure to be within budgeted norms and plan and implement execution of improvement actions for cost optimization | •Framing P&B for the section and monitoring of departmental plans for execution of jobs related to allotted CAPEX and Major maintenance within stipulated budget & time. •Energy mapping, identifying energy conservation schemes and ensure implementation of schemes. •Maintain normal maintenance inventory within budget. •Compare electrical maintenance expenses on monthly basis and compare actual expenses against budget and take action to reduce variants •Suggest and implement measures in design/ modification for cost reduction •Carry out half yearly analysis for the consumption of spares and make action plan for optimized consumption •Assist in data collection, information to identify opportunities and Bottlenecks •Manage the inventory at an optimized level to minimize the working capital while ensuring the plant requirements and risks are addressed •Verify contractor bills for accuracy and certification of quality •Interact with vendors, contractors, OEM suppliers for technical discussions to freeze technical specification & scope of supply for procurement at optimum cost •Provide inputs to the DH in Planning& Budgeting for the Section |
| KRA4 | MIS Reports and Documentation: Ensure timely update of all documents of the section | •Timely preparation of MIS report and all relevant documents •Ensure update of documents as per ISO and related •Assist and get timely audits done in the section |
| KRA5 | Improvement Projects execution (Plan, co-ordinate & monitor execution of various projects & schemes so that they are completed within the stipulated time & budget) | •Preparation of estimation for various improvement projects & schemes for project execution •Project scheduling •Support in planning & execution of projects, schemes, and major maintenance requirements as per target •Perform debottlenecking of problems by interaction with suppliers and identifying alternate methods •Preparation of requirement of Instrument in coordination with Project people based on P&I Diagram. •Ensure execution of instrument jobs are as per schedule and within budgeted cost. |
| KRA6 | System Management (Sustainability & WCM): Implement and adhere to statutory compliances. Environment & Sustainability and systems like IMS, WCM and ISO Supervise & monitor quality systems (ISO, EMS, WCM, OHSAS, ICSA) | •Monitor quality systems in the section for improving performance as per quality and environmental standards •Implement IMS 9001, 14001, 50001, SA 8000, OHSAS 18001 & WCM practices & other systems in the Section •Monitor daily abnormalities & take corrective action and implement counter measures recommended during audits •Implement periodic sustainability audits as directed by Sustainability Cell and other audits •Implement corrective action as reported in audits •Monitor implementation of processes for accident free operations/ Maintenance and compliance of all safety requirements as stipulated by the Factories Act & environment related statutory requirements •Ensure adhering to Compliance of recommendations of breakdown analysis, II recommendations, Near miss recommendations, PSM, ,SO,CFSA & SAM in designated areas •Ensure adherence to SO schedule, active participation as IISC & MIQA SC team member and various other responsibilities awarded through many safety platforms as & when decided by Management. •To comply the implementation of SOPs and JSAs in the section and generate improvement ideas, IMPs and EMPs in designated areas |
| KRA7 | System Management (Safety, Sustainability & WCM): Implement and adhere to statutory compliance related Environment & Sustainability and systems like IMS, WCM and ISO Supervise & monitor quality systems (ISO, EMS, WCM, OHSAS, ICSA) | •Monitor adherence to safety norms & safe operational procedures •Ensuring electrical installations are maintained as per Indian electricity acts & rules. •Facilitate periodic annual testing & inspection of electrical installation by Chief electrical inspector. •Train the team to handle emergency situations like Liquid Chlorine leakages etc. under Disaster Management activities •Ensure safe working conditions & practices and implementation of safety procedures, audit point’s measures & ensure training on safety measures •Encourage employees for participation in Kaizen, Suggestion Scheme, etc. and ensure implementation of audit finding |
| KRA8 | People Development & Management: Maintain a congenial work culture by effective management of people to improve productivity, growth & motivation levels of employees to institutionalize best organizing practices in the Unit | •Maintain discipline and grievance handling staff and workmen and other subordinates •Inculcate in team the group values/policies/ vision/ mission & objectives •Motivate employees for stretch targets through team building and two-way communication •Co-ordinate with HR Team for monitoring the development of FLOs, staff and workmen •Setting of performance targets & KRAs, performance assessment, training need identification, individual development plan and communication of role clarity. •Recommend trainings for skill development and ensure development of team members •Proactively train engineers/FLOs/subordinates •Implement HR practices and maintain shop floor discipline •Provide technical support to team on various issues •Monitor the deployment of manpower resources, with the intention of controlling OT without affecting the smooth running of plant •Encouraging multi-skilling as and when possible. •Playing the role of the trainer in imparting the technical know-how of key machinery/equipment or system |
