Designation: Assistant General Manager
Updated: March 27, 2023
Location: Gujarat, India
Organization: Cement


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Key Result Areas
Supporting Actions



Pyro-processing Energy Cost optimization of 2 clinkerization Units. Accountability : To plan and drive initiatives for and ensure reduction of pyro-processing energy cost of 2 Units.

• Specific heat consumption of clinker across business, Actual Vs. Target, UOM \xe2\x80\x93 kcal per Kg clinker.
• Specific power consumption of clinker across business, Actual Vs. Target, UOM - kwh /kg clinker,
• Major initiatives taken for energy reduction, UOM \xe2\x80\x93 Approved Vs Implemented.

To identify potential avenues where cost effective savings could be achieved. To discuss with Stakeholders and generate and finalize the best possible options. To monitor and review performance of two kilns on regular basis and evolve solutions to address the problems and also strive to improve efficiency on a continuous basis. Work out initiatives towards ensuring mandatory compliance requirement particularly emissions, NOx, SOx etc. To be aware and updated on latest available technology. To select latest and best available technology for our kilns ensuring (a) plant maintainability and reliability (b) plant efficiency in terms of specific power consumption and specific heat consumption. To provide inputs and recommend technology for upcoming projects.


Diagnostic studies of Raw/Coal mills/Cement Mills for reduction in Sp.power consumption, Improvement in mill productivity, de-bottlenecking and imparting fuel/raw material flexibility. Accountability: To perform diagnostic studies for Raw /Coal Mills with objective(s) of reduction in sp.power consumption, Improvement in mill productivity, de-bottlenecking and/or imparting fuel/raw material flexibility and to prepare and implement action plan (including capex) based on the studies.

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  Rawmill/Coal mil/Cement Milll productivity \xe2\x80\x93 Actual Vs. Budget, UOM \xe2\x80\x93 TPH
• Rawmill/Coal mill/Cement Mill Sp. Power consumption \xe2\x80\x93 Actual Vs. Budget, UOM \xe2\x80\x93 kwh/T material
• Rawmill/Coal mill/Cement Mill fineness \xe2\x80\x93 Actual Vs. Target, UOM \xe2\x80\x93 % residue on 90/212 \xc2\xb5m.For Cement Mill:Blaine in M2/Kg

To monitor and review AS-IS performance mapping of all grinding mills (Raw/Coal/Cement mills) To monitor and revirew of day to day performance of grinding mills through MIS, to seek clarifications from stakeholders in case of deviation from desired performance level, to analyze reasons for sub-optimal performance of the grinding mills, to recommend action plan for improvement in objective(s) To monitor and review diagnostic study/plant audit for grinding mills for improvement in productivity, energy efficiency and de-bottlenecking. To ensure implementation of recommended actions plans. To review capex requirement arising out of recommended action points. To hold technical discussions with various suppliers for finalization of concept/scheme, project scope, deliverables etc. To evaluate capex replacement/modification aimed at performance improvement of grinding mills in terms of productivity/energy efficiency To validate Baseline performance and Performance Guarantee after capex installation.


Timely execution of sanctioned projects of SCW unit Accountability: Project Engineering, execution and monitoring or improved plant performance, plant reliability and productivity, coordinate for conceptualization feasibility study, planning and organizing capex for achieving upgradation, process improvement, plant relaibility by bridging technological gap. Ensure timely completion of capex and major modification within budgeted cost to achieve targeted results.

• Achievement of replaced/modified equipment performance parameter in PG test\xe2\x80\x93 Achieved Vs. Guaranteed, UOM- refer supporting actions.
  • Timeframe for reaching guaranteed parameters of the equipment replaced/modified \xe2\x80\x93 Actual Vs. Agreed, UOM \xe2\x80\x93 No. of Days.
  • Issues cropped up during equipment operation. Actual Vs Target Zero, UOM- Number

To coordinate internal resources and third parties/vendors for flawless execution of projects. To ensure that all projects are delivered ontime, within scope and within budget. To facilitate to define the project scope and objectives, involving all relevant stakeholders and ensuring technical feasibility. To ensure resource availability and allocation. Develop detailed project plan to monitor and track progress. Manage change of project scope, project schedule and project costs using appropriate verification techniques. Report and escalate to management to minimize project risks. Perform risk management to minimize project risks Delegate project tasks based on team members individual skill sets and experience level. Track project performance, specifically to analyze the successful completion of short and long term goals Meet budgetary objectives and make adjustments to make project constraint based on financial analysis.


Aditya Birla Operational Excellence/ISO system monitoring, review and implementation. Accountability: To overseeing on implementation, sustain and continual improvement of following ABOEF process requirements across SCW
To steer proper compliance & Implementation of IMS standard:Ensure the effective implementation of various management systems viz. ISO 45001 & ISO 50001 in the plant as per the standard requirements & other guidelines. 1.Compliance against various WCM audits (5S, BCE, Hygiene etc.). Actual Vs. Target, UOM \xe2\x80\x93 % 2. Slippage in Conducting the monthly GRT & KFA meeting Actual Vs. Target: Zero, UOM \xe2\x80\x93 % Compliance 3. Compliance of IMS & ISO 50001 Internal/External Audit findings closure: Actual Vs. Target: Zero, UOM \xe2\x80\x93 % Compliance

A:Facilitate SCW unit on implementation, sustain and continual improvement of following ABOEF process requirements: 1. improvement in internal customer satisfaction. 2.Develop & drive maintenance strategy & autonomous maintenance. 3.Visual development. 4.Knowledge upgradation. 5.Team performance & monitoring WCM MIS. 6.Ensure 100% compliance against various WCM audits(5S,BCE, Hygiene etc.). 7.Process improvement. 8.New technology adoption & development. 9.Evaluation of Kaizens and suggestions judicially. B: Ensure proper compliance & Implementation of IMS standard: 1. Policy Implementation. 2.Document verification. 3.Ensure zero Non Compliance in internal & External system audits. 4: Mentoring & Drive the associated KFA & GRT as per the ABOE framework & CWCM guidelines. 5.Encourage team and give them the improvement projects & Kaizens to enhance performance & productivity.


Creating implimenting and monitoring Condition Based Maintetnace(CBM) programs Accountability: Plant Availability : Organize NDT test for critical machines and analyze results to recommend necessary action for improving plant availability. Technical Support : Coordinate for checking of correctness of technical specification of indents, updation of PM & MM moudle of SAP for right procurement, inventory control review of PM schedule and equipment history. 1.MTBF/MTTR/OEE of unit operations of TPP, pre and post clinkerization (excluding Packing) MTBF & MTTR Actual Vs. Target, UOM \xe2\x80\x93 Hours. OEE : Actual Vs. Target, UOM \xe2\x80\x93 % 2.Preventive Maintainance Order(PM-07) Actual Vs. Target, UOM \xe2\x80\x93 % completion 3. M-2 notification (Why\xe2\x80\x99Why Analysis). Actual Vs. Target, UOM \xe2\x80\x93 % completion

To monitor and review reliability based system including preventive maintenance systems, vibration analysis and condition monitoring. To facilitate preventive maintenance programs (Inspection, Vibration, Oil Analysis, NDT, thermography etc.) to ensure optimum equipment availability To overseeing in the creation of preventive maintenance routine and bills of materials (BOM) for new equipment. To steer for preventive maintenance work order system with coordinated execution of the area operations and maintenance team

• To take a lead role in analysis and elimination of repetitive problems through root cause analysis, Pareto analysis, statistical review, FEMA and similar technique
• Responsible for the facilitation of continuous improvement processes around equipment availability and reliability.
• To support and guide sustainable improvements in MTBF of major equipments
• Provide ongoing reports as needed on the condition based monitoring program status
• Research solution to technical problems.
• To overseeing SAP system operations in the area of preventive maintenance routine and development with concerned HO SAP team
• To organize technical support training and development of maintenance functions with specific fous on the enterenching reliability concepts within the maintenance group
• To ensure Life value analysis of major items

Focus on SHE (Safety, Health & Environment) along with Sustainability initiatives. Accountability: Ensure compliance of safety standards.Demostrate safety commitment in day to day work and effective participation in safety committee meetings. Ensure timely submission of CSI_CO2 data to sustainability cell and also GRI G4 data .Maximzation of blended cement production .Ensure maximum 35% usage of flyash in PPC and maximize blended cement production to reduce CO2 emission. 1.Timely submission of CSI-CO2 data and GRI-G4 data to Sustainability Cell-HO: Actual Vs. Target, UOM \xe2\x80\x93 % Compliance 2.Implementation of applicable safety standard Actual Vs. Target, UOM \xe2\x80\x93 % Compliance 3.Timely submission SO and any incidence/accident Actual Vs. Target, UOM \xe2\x80\x93 % compliance 4.Timely closing of closing of open points of safety audits and compliance of RCN/BCN Actual Vs. Target, UOM \xe2\x80\x93 % compliance 5.Ensure no fatal accident in our department Actual Vs. Target-0, UOM \xe2\x80\x93 Numbers.

100% implementation of all applicable safety standards in department with target of zero injury and no hazard to men, machinery, environment and health of employee deployed in respective department To ensuring whoever is working in department from top to last person should confident about \xe2\x80\x9cI know my job\xe2\x80\x9d, \xe2\x80\x9cI know the hazards associated with my job and I applied control measures\xe2\x80\x9d & \xe2\x80\x9cI escalate to my senior\xe2\x80\x9d Implementation, adherence of Progressive Consequence Management and taking needful action without Effective contribution in respective safety subcommittee, daily walkthrough round, be visible felt leader and sharing view in apex safety meeting for building and inculcating strong culture of safety.

• Ensuring self and team timely report or submit SO, any incident or accident along with taking analysis and corrective actions in respective systems.
• Creating awareness among team about taking care of self and team health and environment aspect for sustainability
• Motivating and bring new technology, innovation way of saving natural resources like water, power, controlling on air pollution ec with sustainable initiatives
• Ensure to completion of abnormalities observed and reported in daily walk through across department.
• Adhering of all safety precautions on the site and off the site
• Ensuring time bound action for closing out for audit (FPSA,SPSA,TPSA and External Audits) findings before target date and compliance of all applicable RCN/BCN recommendations.

Qualifications:

Bachelor Of Engineering,Master of Engineering,Bachelor Of Technology,Master In Technology
Minimum Experience Level:
10-20 Years

Report to:
General Manager