Job Purpose
Plan direct, monitor and organized the Electrical installation & project activities in CA, VAP & PA 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.
Job Context & Major Challenges
- Job Context & Major Challenges
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
- Optimizing manufacturing processes to improve efficiency, reduce costs, and increase productivity is a continuous challenge. It requires identifying bottlenecks, optimizing raw material usage, streamlining production flows, and implementing advanced process control techniques,
- Energy costs can be a significant expense for chemical manufacturing plants. Optimizing energy consumption, implementing energy-efficient technologies, and exploring alternative energy sources can help reduce costs and enhance sustainability. However, the complexity of energy management in chemical processes presents challenges
- Developing robust risk management strategies, emergency response plans, and ensuring employee safety require continuous efforts and investments.
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)
KRA1 1. Plant Maintenance: Plan, monitor & guide the Electrical teams for planning & execution of operation & maintenance activities to ensure uninterrupted operation
of the plant to achieve targeted production
- Approve the prepared Preventive Maintenance (PM) schedule with appropriate task for PM and monitor timely maintenance of electrical euipments by implementation of Preventive and predictive maintenance schedule. Align the plan with production planning and schedules
- Monitor timely replacement of equipmnents and timely procurement and implementation
- Ensure the uptime and maintain electrical equipments in a healthy condition for better quality, efficiency and prolonging life
- Guide team to prepare the SOPs especially for critical technical aspects and approve them and effectively communicate the approved SOPs to all concerned and monitor the adherence to them
- Support Section Heads for availability of necessary resources (manpower, material, etc.) so that corrective actions are taken on time
- Support Section Heads with technical inputs for root cause analysis against failures and for repetitive and recurring nature of failures and ensure correct strengthening activities are planned and taken up
KRA2 2. Plant Efficiency, Continuous Improvement & Energy Conservation
Coordinate and analyze the process conditions to improve the operational efficiency and energy conservation through better maintenance
- Identification & estimation of energy improvement schemes along with schedule
- Optimize energy cost with special focus on cell power & auxiliary power by regular monitoring and giving feedback to operation team for correction
- Plan for development & implementation of equipment modification / energy conservation to cater production process changes, productivity and product quality enhancement
- Source feedback from internal & external customers & identify improvement potential for reduction in maintenance cost
- Assist Operation for energy balancing & minimizing the losses
- Carry out energy audits in departments and assist third party audits as per Management guidelines
KRA3 3. Project Execution (If Any)
Plan, coordinate & monitor execution of various projects & schemes related to Electrical so that they are completed within the stipulated time & budget
- Preparation of estimation for various projects & schemes for Electrical Equipments & Accessories and for project evaluation
- Assist project team in preparation of project schedule
- Support in planning & execution of Electrical projects, schemes, and major maintenance requirements as per the target
- Perform Debottlenecking for Electrical equipment problems by interaction with suppliers and identifying alternate methods
KRA4 4. Planning, Budgeting, Cost Control & Synergies
Plan, coordinate & prepare maintenance budget for the Electrical Department for targeted level of plant utilization
- Prepare annual budgets (Revenue & Capex estimates) for Electrical maintenance of the plant in consultation with process Department Heads
- Monitor the Maintenance expenses on monthly basis and compare actual expenses against budget and take action to reduce variants
- Monitor and guide management of the inventory at an optimized level to minimize the working capital while ensuring the plant requirements and risks are addressed
- Facilitate Purchase Department for development of vendors for spares & services
- Bring in cost awareness across the department by close interaction
KRA5 5. Developing vendors: Explore and deploy alternative vendors while evaluating technical feasibility
- Coordinate & decide the correct technical specifications for new items to be developed
- Float inquiry to various vendors and give technical understanding to them
- Compare the technical feasibility of the received offers and the technical competency and the strength of the vendors
- Compare the offer from technical point of view and guide the purchase department to take appropriate decision
- Support purchase department with technical standards and inputs and get involved in technical settlements of bids / offers / order finalizations
KRA6 6. System Management (Safety, Sustainability & WCM): Monitor adherence to statutory compliance related to Safety, Health and Environment & Sustainability and systems like IMS, WCM and ISO
- Supervise, monitor and implement IMS 9001, 14001, 50001, SA 8000, OHSAS 18001 & WCM practices & other systems in the plant
- Support and implement periodic sustainability audits as directed by Sustainability Cell and other audits
- Review audit reports and plan for improvement
- Plan, review & monitor corrective action for internal customer compliances.
- Monitor processes for accident free operations/ Maintenance and compliance of all safety requirements as stipulated by the Factories Act & environment related statutory requirements
- Monitor adherence to safety norms & safe operational procedures
- Facilitate statutory testing of vessels
KRA7 6. System Management (Safety, Sustainability & WCM): Monitor adherence to statutory compliance related to Safety, Health and Environment & Sustainability and systems like IMS, WCM and ISO
- Ensure training of team to handle emergency situations like Liquid Chlorine leakages etc. under Disaster Management activities
- Monitor compliance to effluent norms set by pollution board
- Ensure safe working conditions & practices.
Ensure implementation of safety procedures, audit point’s measures & ensure training on safety measures
- Comply with factory, boiler, and environmental related statutory requirements
- Encourage employees for participation in Kaizen, Suggestion Scheme, etc. and ensure implementation of audit findings
- Review the role as assigned from the WCM committee or the reporting manager.
- Review daily abnormalities & ensure for corrective action.
- Review counter measures recommended during interdepartmental audits.
KRA8 7. People Development
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
- Set performance targets & KRAs and conduct performance assessment, training need identification of team members and communicate role clarity to each one
- Maintain discipline and grievance handling of the team
- 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 team
- Recommend trainings for skill development and ensure development of team members
- Plan for career development for subordinates
- Implement HR practices and maintain shop floor discipline
- Oversee the training is being given to identified persons for reducing skill gap
- Develop the team members for Talent Retention
- 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
- Take lead for multi skilling by deploying man power for task oriented jobs
KRA9 8. Review SOPS: To review and approve SOPs and work instructions for maintenance and breakdowns for smooth and safe sectional operations.
- To ensure that the safety standards and requirements are made an integral part of each and every activity carried out at the shop floor.
- Review the SOP with inputs from the direct reports and considering all the critical aspects of the Job and get it approved from the reporting manager.
- Ensuring the communication of the duly approved SOP to all concerned and ensuring adherence to them.
