AH Mechanical - Reliability Professional

Job Purpose

Job Purpose Description

Job Context & Major Challenges

The Sheet rolling at Belur (very near to Kolkata) was the first plant of Indal to be set up way back in 1943. The initial capacity of the plant was 2500 tons per annum. Over the time, there has been numerous expansion and modernisation and the present capacity of the plant is about 52000 tons per annum.

Since the plant is very old, the equipment and the technology are quite outdated except for certain pockets of excellence like SMS Cold Rolling mill. The plant has the usual baggage for outdated practices. But over the last three years there has been significant restructuring and the attitude of the workmen and practices have undergone a sea-change. The strategic direction of the Hindalco Sheet Business is shifting towards more value added as Hindalco is priced out of the common segments. As a result, the value added share for the plant output has seen significant increases. The value added output do not come cheap but calls for substantial changes in workmanship and customer orientation. The plant has been able to meet the challenges.

Along with the modernisation in plant and equipment, the business processes in the plant have also been modernised. An ERP system based on Oracle and Orafin has been successfully implemented in the plant.

Key Result Areas

• KRA1 Accountability: Preventive Maintenance: To achieve zero breakdowns by adhering to the maintenance schedule. Tracking the breakdown and to find a trend of the break down in the equipment. To work out Why-Why analysis and find the root cause of a problem. Implement the Kaizen Idea for Continual Improvement. To maximize the P.M Adherence during the preventive maintenance jobs.
• KRA2 Equipment Reliability: Improving equipment reliability by designing changes in equipments. To implement subtle changes in the design stage of equipment parts to increase the factor of safety and to eliminate the design related defect that lead to breakdown.
• KRA3 Spares & Cost: Monitor spares and track costs to keep within P&B. Tracking the record of the spares. Monitoring the condition of spare regularly. Control of Hydraulic Oil Consumption and its accessory element. Reduction of Downtime hrs
• KRA4 Safety & OPEX: Removing unsafe conditions and adhering to OPEX. To adhere with the monthly CO2 Checking. To eliminate the unsafe condition. House Keeping Related jobs. To adhere with 5-S internal auditing. Monitor and eliminate the unsafe acts and conditions for zero accidents and incidents in the Dept. 100% compliance with statutory requirements for Cranes. Ensure safety plans are adhered to as applicable in the department with respective manufacturing group, safety subcommittee. To flow the culture of OPEX in the department. To be a member of Self-maintenance team to implement its standards
• KRA5 Maintenance - Planning the mechanical maintenance activities of the machines (Like SMS Mill, Bliss cold rolling Mill, Annealing furnaces, Finishing line like Heavy slitters, Heavy Stretcher unit, Old heavy cut to length, all shearing machines) on regular basis to extend the machine life. Effective maintenance planning to optimize machine intervention period. Debottlenecking activities of the mechanical aspects of all key equipments. - Control R&M expenditure to meet the target by monitoring operating costs and ensuring corrective actions as necessary. - Planning , monitoring and controlling spares inventory to improve operating costs. - Initiate proactive measures through periodical audits and condition monitoring of all associated machine centers.
• KRA6 ISO AND OHSAS SYSTEM: To maintain all the documents of ISO 9PHONE_NUMBER, ISO-14000, OHSAS-18000 for mechanical department. Close and take corrective action for all the NCR s during external or internal audits
• KRA7 Environment & Energy Management: - Ensure Compliance to ISO 14001. - Ensure Statutory Compliance w.r.t. conditions of Pollution Control Board. - Improve Environmental performance of the Plant through specific projects. - Reduction of Plant Water Consumption and Discharge. To implement in-house developments for energy saving activities
• KRA8 Projects: - Identify the needs for technology improvement and acquiring new assets through knowledge up gradation and interactions. - Planning and monitoring of capex projects within budgeted time and cost meeting targeted deliverables. To improve power productivity of the plant, implement the energy saving projects
• KRA9 HRD Activities: To educate, motivate and involve employees in the department in fulfillment of departmental objectives, prepare annual training plan. Maintain the administration of the Mechanical Maintenance department and control the overtime below the target

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