PF Mechanical (Cement Mill)

Job Purpose

Supervise, monitor & day to day planning for operation and mechanical maintenance of Packing Plant of Line No. III , to fulfil the despatch target timely at optimum cost by maintaining environment & safety standards.

Job Context & Major Challenges

Vikram Cement is located at Jawad in Madhya Pradesh. It has 3 operating lines with the total installed capacity of 2.5 million ton per annum which has been further expanded to 3.0 million ton per annum thro de-bottlenecking of all the three production lines.

Main equipment s for Line no.1 and Line No.2 was supplied by M/s KHD Humboldt Wedag Ltd., Germany, M/s Loesche and for Line No.3 by M/s Krupp Polysius, Germany with Roller Press Technology in Pregrinding circuit and high efficiency separator in Raw Mill and Cement Mill. For better control of quality of Input Limestone Gamma Matrix has been installed at Limestone Transport belt.

The technical know how and packers are supplied by M/S Haver & Bocker, Germany for line I, II & M/S Enexco for line III, having capacity of 90 TPH, 90 TPH & 180 TPH respectively. Mechanical maintenance and operation activities for Packing Plant Line III is looked after by Job Holder.

The Job Holder is responsible for Line No. III Packing Plant mechanical maintenance, operation activities, storage / extraction of Cement from Silo.

• Major Challenges
• Hurdle in Cement bag Loading.
• Weight variation in Cement bag.High dust emission.

Key Result Areas

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

• KRA1 Plant Availability
• Should have exposure of planning for safe & quality maintenance and trouble shooting of Ball Mills, Roller press, ESP & material handling equipments to maximize plant availability for achieve targets of cement grinding . - Supervise PM & Maintenance schedule for abnormalities and their elimination.
• Identify root cause of failures, repeated breakdown and act for their elimination.
• Supervise jobs in Corrective Maintenance, Preventive Maintenance, breakdown maintenance, shutdown maintenance.
• Refer chronic problem to Superiors advise and remedial measures.
• KRA2 Cost Control/Cost Reduction
• Monitor maintenance expenses of cement mill to operate in budgeted norms. - Compare actual expenses against budget and take action to reduce variance.
• Suggest measures for improvement in Design/metallurgy/modification/material structure for cost reduction.
• Increase use of in-house resources for fabrication.
• Monitor lubricant consumption monthly basis & take corrective action.
• Monitor false air leakage and take action for arrest.
• KRA3 Modifications/ Improvements
• Identify improvement area and supervise for Improvement/Modification of Cement Mills to improve productivity. - Assist in data collection, information to identify opportunities, bottlenecks, through benchmarking, performance review, development and suggestions.
• Supervision of Schemes for modification / changes.
• KRA4 System Implementation
• Having exposures of implementation of ABG safety standards at site .
• Having exposures on SAP system.
• Having exposures on systems (ISO, EMS, WCM, OHSAS). - Daily Jishu-Hozen and Fuguais/ abnormality registration and corrective action.
• Implement countermeasures recommended during inter-departmental audits.
• Implementation of safety and pollution control measures.
• Arrange to checks for hoist / pressure vessels / chain pulley block as per safety standards.
• Preparation and execution of Kaizen Schemes.
• Develop One-Point Lesson and impart training.
• Maintain 5 S in alloted area
• KRA5 Material Procurement
• To insure availability of spares for maintenance, modification & project activities Indentfy spare parts requirement
• Calling offer from vendors
• Indenting of material
• Follow up with purchase/ vendors
• Inspection of material