Job Purpose

Job Purpose Description

Job Context & Major Challenges

Job Context –

Birla carbon unit Renukoot established in 1988 with capacity of 20000 TPA to cater the need of Tyre Industry and to supply steam to Hindalco & subsequently capacity increased to 60000 TPA in 1993 and subsequently increased to 70000 TPA in 00-01 by debottlenecking. The unit has obtained ISO/TS16949, ISO 14001, OHSAS 18001, IQMM level-7 and TPM excellence award. Mechanical department role is to maintain trouble free running of all mechanical equipment in the plant utilizing limited available resources for materials and expect services due to remote location and also within stringent breakdown and maintenance cost targets. Department has to comply all the different standards of quality, safety and environment adopted by the unit.

Major Challenges –

To produce consistent product quality( Cpk more than 1.33 in all Grades). To minimize off spec generation through effective participation of shift team in process change and side change over activities. To meet high expectation s of intern customers (QC & WH) through effective implementation of parameters.oved grades (both HARD & SOFT) in terms of product quality & value addition to the customer. Our major thrust is continual improvement in productivity, cost of quality & in process variations resulting in internal/ external customer satisfaction. All the pollution related activities are controlled and monitored as per legislative and regulatory requirements. Evaluation and root cause analysis for customer complaints pertaining to product quality is being performed for taking appropriate corrective & preventive actions. Participate culture is encouraged and motivated through QC, WCM, KSS, 5-S activities. Development of departmental employees is being done by identifying their training needs & providing training for effective execution of process activities.

Major Challenges –

To produce consistent product quality( Cpk more than 1.33 in all Grades). To minimize off spec generation through effective participation of shift team in process change and side change over activities. To meet high expectation s of intern customers (QC & WH) through effective implementation of parameters.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 Production

Ensure trouble free operation of the production processes for achieving quality produ

ction and productivity. – To implement production plan

• Intra/Inter dept. coordination for required jobs in the shift
• Resource planning as per shift requirements.
• To follow all SOPs strictly as per QMS.
• To follow preventive and predictive maintenance Schedule in coordination with Engg depts.
• To guide and maintain all process parameters within allowable range.
• Routine plant rounds for identification of abnormalities and taking corrective actions.
• Maximise the production ratings with a consistent Quality.

KRA2 Quality Control

To Control the Quality of product within set standards so as to ensure quality production. – To monitor and maintain key process parameters as per product characteristics.

• To ensure timely inspection of product quality at each process change to reduce off spec generation.
• To apply Statistical Process Control techniques to establish product and process capability.

KRA3 Cost Control

Optimum utilization of Resources & waste minimization to contribute in achieving Purta norms. – Efficient utilization of resources to have maximum productivity.( Yield)

• Monitoring consumption of inventory in shift.
• Continuous monitoring of cost incurred during Shift in reprocessing, energy loss, waste generation , breakdown, & other quality indicators.

KRA4 Reduction In Plant Stoppage

Reduction in Plant B/Dn. due to process upset to achieve higher productivity.

(This is critical due to inherent nature of industry.) – To safely & timely hand-over of equipment s to Maintenance department for Preventive & Predictive Maintenance. & also provide safety instructions during the activity.

• To check the performance of Equipment s after Maintenance.
• To take decisions to resume back to normal operation at the earliest.

KRA5 QMS

Compliance to all systems, Procedures & Work Instructions for achieving high standard

s of Work Culture. – To motivate & encourage participative culture through WCM, quality circle, kaizen, 5-S activities.

• To percolate and develop understanding of all QMS standards among the team members.
• On job training of the shift team.
• Sharing departmental expectations and performance during monthly departmental meeting and prepare action plan for improvement projects.

KRA6 Safety

Execution of all activities with utmost importance to Safety. – Supervise regular inspection during the shift to identify problem areas and unsafe practices, unsafe work places & to ensure that agreed corrective actions are fully imp

lemented on time.

• Periodically educate all Shift employees on the safety procedures & ensure use of Personal Protective Equipments.
• To Prepare Safety Work Permit before carrying out the maintenance jobs.
• Facilitate First Aid / Medical attention as required by the employee.

KRA7 Pollution

Monitor and review that all effluent from plant premises are within Pollution Control

Compliance Norms. – Ensure that effluent discharge during the shift is within approved limits.

• Ensure optimum consumption of chemicals .
• Ensure appropriate steps as required to control / stop emissions at the earliest opportunity , even it requires stoppage.

KRA8 Process MIS

Collate data regarding shift working & communicate to superiors for their necessary information & action – Preparation of shift wise status report after collecting feedback from assisting team and giving feed back to unit head, head production, other departments for actions.

• Required data analysis and MIS reports preparation

KRA9 Plant accountability

Ensure smooth functioning of the plant beyond office hours to sustain quality operations.

Safe and smooth operations in terms of technical and administrative functions. -Co-ordination with other dept. shift in-charges by seeking and giving feedback as and

when required.

• Taking decisions as a team leader for total plant operation in shifts related to smooth functioning of the plant.
• Advising other dept. personnel in shifts for solving operational and administrative issues.
• Initiating appropriate action in plant emergency.

Desired Skills and Experience

Engineering, Operations, SAP, Report Preparation

SH Regional Supply Chain

About the job