Job Purpose:
Plan, implement, review and control of all activities such as planning and executing of Projects, CAPEX proposals with optimum cost and resource, identifying, analyzing and implementing improvement opportunities to enhance technology, process, productivity, reduce energy and cost. Institutionalizing business excellence processes and quality systems (IMS).
Formulate, monitor and ensure implementation of plans
- for achieving production (Sulphuric Acid & IBAP) targets with minimum downtime and at budgeted cost so as to enable the Unit to achieve cost effective production
- Producing product to meet required customer specification
Undertake regular preventive & predictive maintenance for improved process reliability and reduced downtime
Job Context & Major Challenges:
Context:
The two product AHF and Sulphuric acid giving great contribution in revenue of TANFAC. At the same time there is a market threatening for both the product due to china and local markets intervention. The increase in raw material price is another threatening to sustain in the business. So to sustain and grow in business it is essential to find new value added products using AHF and sulphuric acid.
Considering market conditions and for sustainability, it is imperative to reduce cost, improve efficiency in all functions and processes at all plants. The position is responsible for implementing various/ multiple initiatives such as up gradation of technology, conducting process improvement studies, energy / cost saving measures including energy audit, inspection of equipment conditions, debottlenecking jobs, re-engineering, implementation of Kaizens/Innovative projects, new projects including various CAPEX, to make the operations with low cost and maximization of capacity utilization.
Challenges:
- Capacity utilization in IBAP and AHF
- Sustaining production of Sulphuric acid
- New product development
- To develop & deploy technical services as an improvement function & excellence processes as practice/culture with available resources having less or no exposure in such systems.
- To identify areas of improvement for efficiency and productivity enhancement.
- .To develop cost economic solutions for achieving benchmark levels.
Right selection, engineering and execution of Capex projects within given cost and time.
4) Principal Accountabilities
Accountability
Supporting Actions
1. Production/Operations: Plan, monitor and ensure achievement of the production targets within the budgeted costs
- Lay down production targets, schedule and ensure implementation and ensure marketing schedules are also met in the plan
- Review Plant performance on daily basis
- Ensure implementation of set operation parameters and consumption norms
- Coordinate with other functions for resource mobilization to optimum extent
- Review cost drivers through monthly performance reviews
- Motivate team for making improvement through initiatives and bring cost awareness across the plant
- Timely communicate management expectations down the line
2. Operational Efficiency: Work towards achieving higher operational efficiency
- Keep oneself abreast with latest technological developments
- Benchmark operation parameters with the world’s best
- Coordinate with technology supplier/CTC/Technology Cell for achieving benchmark processes
- Prepare action plans for efficiency improvement and ensure implementation
- Decide on key operational parameters and efficiency targets that are to be monitored and achieved
- Develop and ensure implementation of continuous improvement activities like Six Sigma approach, Kaizen activities and suggestion schemes
- Ensure timely availability of budgeted resources to the team
- Coordinate with all other functions for process/issues
3. Product Quality: Ensure quality of the product so as to meet customer requirements
- Monitor the process and quality parameters and ensure implementation of action points
- Monitor and oversee Customers quality requirements
- Ensure investigation of customer complaints and implementation of corrective actions
4. Optimum Energy Consumptions: Ensure optimum Energy Consumption and meet compliances as required/directed
- Identify priority areas for improvement and ensure implementation of schemes for energy savings
- Critically review daily power consumption figures
5. Project / CAPEX Management
Plan, execute, monitor and review all project / CAPEX proposal with optimum cost / resources / time to achieve the objectives.
- Estimate, review and monitor project budget and timelines.
- Initiate applicable course corrections
- Concept, basic engineering, spec. for tender / procurement, Review and feedback on technology
- Review offers, technical clarifications/comments with vendors
- selection of equipment/system /supplier
- Interact with technology suppliers, consultants, if any.
- Review of detail engineering
- Organize on-site execution
- Coordinate with other departments
6. Technical Up Gradation / Development
Identify, analyze, implement and monitor all improvement opportunities such as technological up gradation, process improvement studies / audit to achieve improvement in productivity / processes / efficiency of operation
- Identify improvement opportunities with inputs from Benchmark indices, studies / audits.
- Analyze feasibility, cost economics
- Compare latest technology with available equipment / process in plants.
- Interact with technology suppliers, industry peers.
- Study latest installations
- Prepare & submit proposals
- Monitor, review operation, equipment & process performance and Benchmarking critical parameters.
- Identify bottlenecks in process / equipment
- Identify & propose improvement projects/ schemes/action.
- Monitor results after execution of project/ schemes / action.
- Coordinate with other Depts.
7.Technical Cell / Services:
Study & review major technical issues in plants, recommend corrective/ preventive and improvement measures.
- Follow up for Major and repetitive breakdown analysis with all concern departments.
- Follow up for Why-Why and final actionable recommendations.
- Deploy RCM for critical equipment(s)
- Study major technical issues in plants for solutions
- Provide technical support to O&M team towards improvements
- Monitoring of special task forces formed for specific issues
- Compare group units operational key indicators in coordination with their technical cells
- Draw conclusion and identify improvement action from benchmarking exercise.
- Organize necessary external & internal audits
- Coordinate visit of group unit and other visiting technical team.
- Analysis of block proposals for return, justification and feasibility.
8. Planning & Budgeting, Cost Management
P&B for Capex. Projects towards controlling cost, achieve targeted cost savings through continuous improvement.
- Cost control measures for Capex. projects
- Plan and co-ordinate to reach target savings through Kaizens, implementation of best practices & cases with repetitive potential.
- Monitoring of QCDIP targets vs actuals
9. Safety & Environment:
Monitor the implementation of activities required for maintaining good housekeeping and safety standards of the area so as to achieve ZERO Pollution and ZERO accidents.
- Monitor the implementation of corrective actions for rectification of leakage / spillage points and unsafe areas / practices.
- Educate & Motivate the subordinates in adopting safe working practices
- Monitor and analyze accidents and near miss cases and implement corrective & preventive actions for elimination of the same
- Conduct safety & environment audits and implement corrective actions for abnormalities identified during these audits
10. People Development:
Build & sustain a congenial work culture by effective management of people to improve productivity, growth & motivation levels of employees to institutionalize best organizational 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
- Ensure 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
- Recommend trainings for skill development and ensure development of team members
- Co-ordinate with HR Team for monitoring the development of team
- Coordinate and plan for career development for subordinates
- Implement HR practices and maintain shop floor discipline
- Support and guide the team during crisis/emergency
5) Job Purpose of Direct Reports
Section Head (Technical service)
Plan, implement and monitor all activities of Projects including CAPEX, WCM, IMS and technical services / cell, systems / procedures / policies / best practices, periodical audits, maintenance of documents and records to achieve continual improvement and substance.
Section Head (Sulphuric Acid Plant)
Monitor, control and implement plans to achieve targeted production of Sulphuric Acid Plant within budgeted cost meeting production specification, Quality, safety and statutory requirements and Optimize steam generation by maintaining the plant parameter.
Section Head (IBAP)
Monitor, control and implement plans to achieve targeted production of IBAP within budgeted cost meeting production specification, Quality, safety and statutory requirements.
Qualifications:
B.E/B.Tech,B.E./B.Tech (Dist Education)
Minimum Experience Level:
18-20 Years
Report to:
Officer
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