FLE Process

Job Context:- UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The company has consolidated capacity of 116.75 Million Tonnes Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 26 grinding units and 7 bulk terminals. Its operations span across India, UAE, Bahrain and Sri Lanka. UltraTech Cement is also India's largest exporter of cement reaching out to meet the demand in countries around the Indian Ocean and the Middle East.

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.

The focus area for Job holder is to ensure production planning as per business target and coordinating the operation and maintenance activities of plant to ensure effective and efficient running of various equipment’s. Position holder is also responsible for Designing & developing appropriate raw material mix to ensure consistent quality of finished goods to ensure customer satisfaction and no complaints from marketing team.

Major Challenges –

• To create Pollution free environment
• To ensure sustainable improvement in plant operational parameters by consistently improving upon existing processes.
• To sustain fly ash to bring cost effectiveness in production.
• Quality Control during processes & Quality Assurance in products consistency with cost control, on time and Meeting strength criteria of products.
• Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)
  
  

Key Result Areas / Accountabilities

Supporting Actions

Operational Management: Operation and optimization of VRM/coal mill as to achieve the targeted production and Power.

• Continuously check operation and quality parameters of equipment’s and Identify abnormalities if any Inform SH Process and CCR Operators for corrective actions
• Implementation of daily activities as per production planning
• Automise and track VRM/coal mill circuit to avoid idle running of equipment
• Implementation of PM checklist in the section,
• Why-why & PM analysis for process break downs and take corrective measures.
• Daily Trends review and checklist execution Record day wise production and Power Consumption and prepare comparative data for study/analysis.
• Monitoring of power consumption and take corrective action to reduce power consumption.
• Ensure grade wise production as per requirement and correct changeover of circuit ensuring product quality.
• Cross checking of cement blaine whenever it comes abnormal.
• Planning and monitor smooth changeover of cement grade as per requirement
• Monitor and ensure timely replacement of grinding media make-up charge
• Assisting SH P&QC in day to day operation activities to ensure smooth operation to meet the company target with proper coordination with respective departments.
  
  

Cost Control: Process expenses to

operate in budgeted norms and

implementation of improvement

actions for cost optimization.

1 Identifying and bringing to the notice of Section Head for unnecessary interlocks / idle running of equipment’s. Continuous monitoring of trends along with process parameters. Ensure running of power saving equipment in SPRS. Running Raw Mills / Cement Mills in Fuzzy logic control.

• Implement the action suggested to reduce the variance after comparing actual and budgeted cost.
• Use of grinding media within the budgeted norms.
• Evolve schemes resulting in reduction and power cost.
• Monitor false air and idle running of equipment and take corrective action.
• Ensure running of power saving equipment to optimize and reduce power consumption.
• Initiate procurement of grinding media with shutdown planning to optimize idle inventory level.
• Making shutdown PRs and MRs, Indent / Issue the material and coordinate with Contractor
• Control utilisation of contractor manpower & overtime.
  
  

Continuous Improvement & Process Maintenance Jobs

Identify areas for improvements,

conduct focused studies, and

execution of proposals on

modifications /improvements for

Productivity Improvement.

• Coordination for Refractory work in shutdown activities and shutdown jobs at various places. Supervise for correct installation of castables. Take no load trials of standby equipment’s. Change overs whenever required. Co-ordination for shutdown activities assigned.
• Assist in data collection, analysis of data and implement corrective action based on action plan.
• Analysis of data and feasibility study (Cost benefit analysis) by application of PM analysis.
• Process flow measurement and parameter cross check if found abnormal.
• Identification of source of leakage and ensure corrective action.
  
  

Legal And Statutory Compliances

Products licenses, bis requirements /regular statutory fees & networking.

• Prepare documents for proactive renewals, compliance of BIS requirements.
• Ensure the calibration of all laboratory equipment’s maintain record of the same.
• Assuring conformity of test results with the statutory requirements of BIS and internal specification.
• Monitor statutory compliance for process requirements as per i.e. rules.
• Carryout the required checking, testing as per guidelines.
• Timely & accurate payment of statutory fees and ensure no noncompliance in the same
  
  

Quality Control: To supervise, monitor and control quality of raw materials, process intermediates and finish products as

per plan through proper sampling and testing

• Monitor, coordinate and supervise daily samplings and sample preparation of incoming, in-process and finished products material such as Coal, Gypsum, Clinker and Cement.
• Supervising moisture content in raw material and take corrective actions in process.
• Monitor activity of quality management module of SAP & Data feeding.
• Ensuring sampling and testing of all the materials as per plan.
• Supervising the quality data in the lab operation.
• Informing SH P&QC of any deviations in the test results against standards
  
  

Accountability: Unloading & Feeding of Raw

Materials.

Maintain all records and generate MIS in an accurate & timely manner.

• Decide, inspect the location for storage.
• Prepare piles & maintain pile-wise record for quantity and quality.
• Arrange unload coal / raw material outside if pile is full. Arrange transfer outside coal to piles, if required.
• Deploy resources/machineries.
• Discuss / Interact with materials for requirements of various raw materials & Coal.
• Enter the receipts / issue of coal and other raw materials in SAP
• Check stock status daily
• Prepare MIS for consumption / receipts and stocks.
• To ensure timely completion of physical checking of Raw Material quantities
  
  

System Management

(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)

• The system requirements of ISO, EMS, OHSAS, SA 8000 and WCM systems in Cement Mills & Coal Mills thorough the involvement of employees for improving plant working and quality standard. Identify and improvement study and kaizen. Identify & get rectified. Abnormalities. Spillage/leakages. Unsafe conditions/practices. 5S activities. Points emerged in campaigns. Implementation plan for Quality improvement objectives. Improvement of WCM criteria score. EMS targets. Internal customer rating improvement. Statutory compliance. Improvement of OEE/MTBF/MTTR Elimination of muda. Does why analysis. Prepare/present weekly/monthly WCM presentation. Develop one-point lesson. Update WCM activity board Create awareness in team members. Develop visual controls.
  
  

Focus on 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.
• . Housekeeping and Environmental / Safety. Practice of good housekeeping standards with reference to spillages / leakages etc. and environment / safety performance in the section / team area. Monitor performance of dust control equipment’s i.e., GCT, Dust collectors, CO tripping. Using personal protective equipment’s. Participating in WCM activities.
• 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.
  
  

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