Job Purpose
To achieve budgeted production of Clinker,Raw Meal,Fine coal & Cement within budgeted specific power & fuel consumption and fixed cost. Also, ensure safe and smooth operation of Plant & Machinery.
To sustain ISO and WCM activities.
Job Context & Major Challenges
To produce raw meal, clinker, fine coal & cement as per budget. Operating plant keeping low inventory of in process material with variety of low cost additives and with lower LSF of lime stone.
To Adjust All Operating Parameters In Order To Produce Quality Clinker And Cement Within The Norms By The Given Recipe. Major Challenges
High volumetric loading of kiln (>7 TPD/m3)
High thermal loading of kiln (>6 giga calorie/hr/m2)
To achieve 345 days kiln running
To achieve budgeted clinker & cement production in such extreme conditions as mentioned above
Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)
KRA1 Accountability: Process Management:
Organize & coordinate production as per dispatch schedule and ensure optimum production and plant availability from process side by controlling process parameters/ process stoppages to meet targets and customer satisfaction. Daily monitoring of production, monitoring process parameters optimization of process -Continuous interaction with other department for achieving plant run factor
KRA2 Cost Optimization
To achieve less Sp power and fuel consumption Monitoring section wise power on daily basis and take corrective actions
Ensure no idle running of equipment.
Ensure no false air infiltration in pyro and raw mill section
To interact with other departments for brain storming and further optimize
KRA3 Quality Consistency
Monitor & review production of clinker of consistent quality to maintain brand image and improve customer satisfaction. Monitor the test results.
Analyze the reasons for deviation.
Take correction action.
Review of quality of products.
Make changes in ISO standards form continuous improvement.
Check process capability to meet new standards.
Take action to improve process capabilities.
Ensure testing & calibration of instruments for accuracy.
KRA4 Co processing of AFR and *Refractory management Set targets for thermal substitution rate and quantity of AFR in consultation with all concerned
Achieve the targets with minimal impact on production and quality
Maximise AFR quantity and ensure availability of AFR feeding system
- Looking alternate of lower cost quality refractory material without compromising run factor to reduce Fixed cost and by adopting best practices of refractory laying
KRA5 Process People Development
Organise and ensure skill & competency development of people for working improvement in process control area. Identify training needs
Recommend for training
Assignment tasks for job enrichment
Guide job rotation
Take training classes.
KRA6 Plan Process Improvement / Upgradation& *Shut down management :
Plan & implement plant process improvements / upgradations projects/ process parameters for new product, Environment, Safety, Productivity, Process Control & Quality. Identify bottlenecks / Projects for improvements.
Analyse problems
Interact with OEM
Formulate proposal & seek approval
Check process capability.
Guide process optimisation.
Ensure implementation of plan
Monitor progress
Guide corrective actions
- Planning & Budgeting of refractories & other consumables at starting of year and timely completion as per Bar Chart with proper co ordination of Mech, electrical &other departments and completion of job with ensuring safety and quality.
