FLO Safety- Paints Manufacturing- Ludhiana

Job Purpose

Design, plan, organise, co-ordinate, control and monitor quality of all incoming raw materials, Fuels, in-process and finished products through raw mix design,sampling, inspection and analysis at various phases of operations. Coordinate with Packing plant & CCR for timely giving clearance during grade changeover. Guide the plant in producing optimum quantity and consistent quality of products. To co-ordinate, organise and monitor Raw Material Handling within budget limit. Also organise and co ordinate research and development activities for innovation / new upgraded products, in plant to ensure 100% statutory compliance. To compare our cement with competitors for producing good quality cement.

Job Context & Major Challenges

Job Context

UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. It is also one of the leading cement producers globally. The company has a consolidated capacity of 132.45 Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants, 1 Clinkerization plant, 27 grinding units and 7 bulk terminals, post the Century merger. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.

UltraTech, Rawan Cement plant started its Line 1 operation in early 90’s with the capacity of 1 MTPA, commissioned in March, 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March’2013, Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility, currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW, Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch, Germany for grinding limestone and coal, Kiln and cooler from L&T/FLS, Denmark, Combi-Grinding Cement Mill with Roller Press from KHD, Germany, Finish Grinding Slag Grinding Roller Press from Krupp Polysius, Germany, Cross belt analyser from Gamma Metrics USA for on-line analysis of Limestone, X-Ray analyser, Cem Scanner from FLS, Denmark.

As the largest cement producer in India, we continually strive to play a key role in finding effective and responsible ways to preserve the environment - a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management, energy reduction, water conservation, biodiversity management, afforestation and emission reduction which are relevant to the cement industry.

Major Challenges

The captive limestone mines is of marginal grade with high alkali. Raw mix design to ensure productivity and desired quality is a critical task considering the limestone quality.

The higher alkali in clinker affects the progressive increase in strength at all ages with lower later age strength. To be ahead of competition, product quality with these limiting factors is a major challenge.Provide desired quality product to the customers as per the internal specification. Production planning for OTIF deliveries as per the production plan.Handling of raw materials inside the plant to ensure cost effective consistent running of production process (Iron Ore-0.2 Lac MT per annum; Coal-2.2 Lac MT per annum; Slag-3.5 Lac MT per annum; Fly ash-1.0 Lac MT per annum; Gypsum-0.7 Lac MT per annum)

To plan and operate packing facility at Raipur, which is 80 KMs away from plant (BIS licenses for the PSC and PPC are operative)

Analysis of all the samples from the coal washery to ensure cost effective washing and handling of coal.

Key Result Areas

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

KRA1 Accountability- Quality Control

Organize inspection, sampling and testing of all the raw materials, in-process materials and finished products.

Co-ordinate and monitor the production of consistent quality of product. Testing frequency as per the Quality plan on daily basis.

Calibration of test equipment as per quality plan.

Monitor the lab results and guide for corrective actions in case of deviations.

KRA10 Niche market development and support to Marketing on capturing new / emerging markets To understand the requirement of niche / emerging market from TASC.

To develop product suiting to the new requirement.

To organize customer meets and visit key customers for product promotion / entrenchment in the market.

KRA11 Receipt and Acceptance of Wastes, Production and Delivery of Agreed Quality and Quantity of AFR and Compliance with Statutory Requirements

• Develop a receipt plan for wastes to match final AFR agreed specifications based on compatibility of wastes.
• Obtain and maintain plant’s license for TSDF (Treatment, Storage and Disposal Facility).
• Ensure safe storage and subsequent return of rejected waste to the generators’ premises.
• Agree and finalise AFR quality specifications and quantity with Process Team and Business Development Team, to be delivered on regular basis.
• Develop safe storage facility for hazardous wastes and maintain as per regulation and safety requirements.
• Ensure running of pre-processing section and AFR Laboratory to produce required quality of AFR.
• Set Targets for Thermal Substitution Rate and achieve the same.
• Obtain permits for transportation and disposal of wastes from State Pollution Control Board, file returns on waste usage, carry out periodic emission measurements in compliance with the permits obtained.
• Check all documents like Form 11, Form 12, Form 13 and ensure submission to regulatory authorities on time.
• Ensure regulatory compliance from generators and transporters for disposal of wastes.
  
  

KRA2 Optimization of Raw Mix

Design and develop appropriate cost effective raw mix to ensure consistent quality of targeted production. Designing of raw mix as per the available coal and raw material on monthly basis.

Coordination and monitoring for supply of required grade of limestone from mines.

Finalization of the mix composition of the additives.

Guide for addition of fly ash.

Fixing the moduli values.

Cross checking of X-ray calibration.

Develop cost effective raw mix.

Search for right quality raw materials for quality improvement and cost reduction.

KRA3 Research & Development

Organize and coordinate research and development activities for production upgradation, development of new products/attributes as per customers requirements and cost optimization to take competitive markets advantage Guide for procuring selected material

Identify/approve new project.

Draw action plan for project.

Monitor and check the progress and advise for the change wherever required.

Laboratory testing of various products.

Market survey for new requirements.

Customer complaints redressal.

Design of experiments and trial tests.

Coordinate for field trials on approval.

KRA4 Quality Of Coal & Raw Material

Coordinate & ensure quality of raw material and coal is as per agreed standards to satisfy quality requirements. Plan stacking of coal & other raw material based on their quality.

Making of coal and limestone pile as per the standards.

Arrange addition of corrective material required to maintain agreed standards.

Ensure quality of coal as per requirement from coal washery.

Meet/interact regularly with internal customers to take feed back and plan corrective action.

Extend help required to customers in urgency for specific material/coal requirement.

KRA5 Raw Material Unloading & feeding.

Coordinate & monitor timely unloading of raw material & coal from truck/rake and supply of coal & raw materials as per requirement to meet the production targets and satisfaction of internal customer. Take daily round of coal handling area to review stock positions.

Monitor availability of unloading equipment & coordination with Instrumentation, Mechanical and Electrical departments.

Conduct daily performance review meeting.

Discuss the problems and identify actions to be taken to overcome the same.

Coordinate with Raw material procurement dept. for requirement of raw material/coal.

KRA6 Handling & Maintenance Cost Control

Ensure cost effective operation of raw material handling activities. Daily review of consumption and stock.

Consultation with Raw materials procurement head for delivery schedule depending on stocks.

Organise required resources for unloading within specified time limits.

Review the reasons of demurrage and take corrective action.

Monitor inventory & take corrective action for optimization .

Review reason of double handling and take corrective action.

Identify and track key value drivers

Control utilisation of contractor manpower & overtime

KRA7 Production & Material planning Co-ordinate with Marketing / Logistics to obtaining the cement / clinker dispatch requirements.

Plan and schedule the production of various type and cements & interact with concerned departments for 100% compliance.

Plan the raw material requirement and co-ordinate with procurement department for required quantity & quality of material.

Characterization of raw materials on annual basis.

KRA8 Operation, Quality Management of Packing Unit at Raipur To ensure running of laboratory and product testing as per BIS requirement.

To ensure proper weight of the bag on daily basis.

KRA9 Product development To track and anticipate the need of the customer and competitors dynamics.

To ensure development of product and features to satisfy customer requirements.

Development of new products to capture niche market.