Job Description:
Job Context & Major Challenges:
Birla Cellulosic is the latest unit in Group’s Pulp & Fibre Business established in 1998 with latest state of the art technology comprising of DCS control and certain imported equipments. The designated capacity was 63875 TPA. Post-expansion, this will now be scaled upto 133955 TPA.Consequently, it is expected to produce best quality of VSF in the group with consistency and at lowest cost of production and establish benchmarks with the group. The Unit meets the requirement of fibre in both domestic and export market. Post-expansion, a 25 MW extraction mode captive power plant having interdependency with VSF operation is integrated with zero tripping tolerance. There has been continuous improvement on all fronts viz quality, safety, production, productivity, product grades, consumption ratios, environmental aspects etc. These are to be sustained and improved further for providing a competitive edge to the business. Viscose preparation is a chemical process and it involves a sequence of operations. Few important unit operations are: Alkylation, Xanthation, Filtration, de-polymerization, de-aeration , Refrigeration & use of catalyst etc. Control of various parameters in each operation in narrow band is required to maintain standard quality of the final product. It is also required to update the old technology to improve quality product, reduce cost of production, energy conservation & maintain safe work environment etc.
Major Challenges
1. Water consumption in the process is high which would pose challenge during bad monsoon
2. Carrying out rehabilitation, repair and technological innovations in running plant – sustaining production and quality without sacrificing safety and environment
3. Resistance by the Collective bargaining units about bringing technological changes Unit specific Challenges:
4. Machine 1 & 2 were developed in house, it’s very old technology – which limits productivity, quality and cost optimization.
5. Machine 1 & 2 doesn’t have Digital Control System (DCS) which impacts manpower cost and process controls.
6. Line workmen technical competency is not at the desired level due to their current qualification
7. Quality of fiber produced in line 3 is superior compared to 1 & 2 hence effective bargain with customer to accept product from line 1& 2 is a challenge
8. Producing benchmark quality fiber by using in house pulp is a challenge
9. High energy consumption in the process due to usage of old technology
10. Maximizing CS2 recovery from the current level is a challenge due old technology
11. Reduction of Fugitive emission in the work environment which poses health hazard
12. Maintain ing of consistent quality with the existing input raw materials
Key Result Areas/Accountabilities:
Production Planning & Control
1. Plan work schedules for Shift
2. Monitor production status and ensure timely delivery.
3. Identify delays and accordingly adjust schedules to meet deadlines.
4. Assist in production risk assessment and mitigation activities.
5. Assist in new product development and enhancements.
6. Conduct daily meetings to keep track of production schedules.
7. Ensure that finished products meet quality standards and customer specifications.
8. Ensure that finished products meet quality standards and customer specifications.
9. Determine equipment, materials and manpower required to complete production.
10. Resolve production issues and escalate unresolved issues to management promptly.
11. Ensure spares and raw material Inventory are available as per the desired stock levels to ensure no disruption in production activities
12. Monitor and analyze downtime with Root cause to reduce its impact on Cost, Quality and Delivery
Safety & Environment
1. Provide training to employees and contractors (as required) to assure understanding and compliance with Process Safety Standards and requirements of local process safety requirements. (PSM/RMP programs)
2. Identification of Process Hazards Analysis (PHA ) and action
3. Participate in Process Safety Event investigations/root cause analysis to provide guidance to all plants. In conjunction with site management teams, track progress of corrective actions where business wide issues are identified.
4. Coordinate Safety Alerts and other company wide initiatives for their respective plants.
Change management
1. Ensure ABG Operational excellence guidelines are adhered by continuous training, implemented and review by using the RADAR framework of ABG
2. Lead Continuous improvement culture among team members to deliver excellence in operations
3. Identify opportunities for joint improvement projects among departments, vendors and suppliers through CFTs
Project
1. Ensure completion of process improvement projects within a specified time frame while achieving a cost reduction goal.
2. Provide management with project status updates, feedback, and appropriate reporting on key responsibilities and objectives.
Planning & budgeting
1. Adhering to approved P&B and update of the progress made
Customer centricity
1. Share time MIS reports as desired by internal and external customers
People Management
1. Ensure Workmen are aware of their roles and responsibilities and deliverables
2. Create an enabling environment to discuss and share people issues at workplace
3. Encourage and model the recognition culture at workplace
4. Ensure Safety and Environment awareness among employees and training wherever required
Qualifications:
Bachelor Of Engineering,Bachelor Of Technology
Minimum Experience Level:
2-6 Years
Report to:
General Manager


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