Executive- Sr. Executive- Operations (Productions)

Role & responsibilities

1. Production Planning & Target Achievement

• Execute daily production plan for Grinding and Calcination as per production requirement.
• Ensure achievement of daily, shift-wise and monthly production targets.
• Plan raw gypsum feeding, grinding and calcination according to silo levels and downstream requirements.
• Coordinate with Dispatch, Packing and other production sections to maintain continuous plant operation.

2. Grinding Section

Responsible for operation and monitoring of:

• Crusher
• 4-Roller Mill / 6-Roller Mill
• Screw Conveyors
• Bucket Elevators
• Rotary Valves
• Feeding Systems
• Blowers
• Dust Collection Systems
• Gypsum Storage Silos

Key responsibilities:

• Maintain required mill feed rate and grinding capacity.
• Monitor gypsum feed size and ensure proper grinding.
• Maintain required product fineness.
• Monitor mill vibration, differential pressure, motor load and other operating parameters.
• Ensure stable feeding to the calcination section.
• Avoid mill choking, overloading and empty running.
• Optimize mill operation to reduce specific power consumption.
• Coordinate with Maintenance for abnormalities and breakdowns.

3. Calcination Section

Responsible for operation and monitoring of:

• Vertical Calciner / Kettle
• Boiler / TFH
• Coal Feeding System
• ID Fan / Blower
• Rotary Valves
• Screw Conveyors
• Calcined Gypsum Silos
• Associated temperature, pressure and instrumentation systems

Key responsibilities:

• Maintain required calcination temperature and residence time.
• Ensure stable and continuous feeding of gypsum to the calciner.
• Monitor:
• Feed rate
• Calcination temperature
• Material temperature
• Coal consumption
• Airflow
• Draft/pressure
• Boiler/TFH parameters
• Product quality
• Ensure proper calcination and avoid under-calcination or over-calcination.
• Maintain required coal consumption per MT of stucco.
• Optimize fuel and air ratio for efficient operation.
• Monitor calcined gypsum quality and take corrective action whenever parameters deviate.

4. Process Control & Optimization

• Maintain process parameters within the defined operating range.
• Identify abnormal trends before they result in production loss or quality problems.
• Optimize mill capacity, calcination rate and fuel consumption.
• Monitor specific power consumption and coal consumption per MT.
• Identify opportunities for energy and process optimization.
• Maintain operating standards and SOPs.

5. Quality Control

• Ensure required gypsum/stucco quality as per specification.
• Coordinate with the Quality/Lab team for:
• Fineness
• Setting time
• Free moisture
• Combined water
• Bulk density
• Other applicable quality parameters
• Take immediate corrective action in case of quality deviation.
• Maintain traceability between raw material, process parameters and finished product.

6. Equipment & Process Reliability

• Carry out routine inspection of operating equipment.
• Identify abnormal sound, vibration, temperature, leakage, belt/chain condition, etc.
• Immediately inform Maintenance about equipment abnormalities.
• Coordinate with Maintenance during breakdowns and planned maintenance.
• Ensure equipment is handed over safely for maintenance and properly taken back after completion.
• Minimize production loss due to operational issues.

7. Coal Consumption Monitoring

• Monitor daily coal consumption and calculate kg coal/MT of stucco.
• Reconcile coal feeding with production.
• Identify abnormal/excessive coal consumption.
• Maintain daily coal consumption records.
• Work on initiatives for coal reduction and heat recovery.
• Support implementation of coal weighment and automated feeding systems.

8. Silo & Material Management

• Maintain optimum levels of:
• Raw gypsum silo
• Ground gypsum silo
• Calcined gypsum/stucco silo
• Avoid silo overflow and low-level situations.
• Coordinate grinding and calcination operation based on silo availability.
• Ensure proper material transfer and avoid unnecessary material handling losses.

9. Shift Management

• Supervise operators and helpers working in Grinding and Calcination.
• Allocate manpower effectively.
• Ensure proper shift handover.
• Maintain shift production and process reports.
• Ensure operators follow SOPs, checklists and operating instructions.
• Monitor operator discipline and performance.

10. Safety

• Ensure safe operation of Grinding and Calcination equipment.
• Ensure PPE compliance.
• Follow LOTO requirements during maintenance.
• Ensure safe handling of hot material, coal and rotating equipment.
• Report unsafe conditions immediately.
• Ensure compliance with plant safety procedures and emergency protocols.

11. Reporting & Documentation Maintain:

• Shift production report
• Grinding production and operating parameters
• Calcination production report
• Coal consumption report
• Specific power consumption
• Equipment running hours
• Breakdown/production-loss details
• Silo stock levels
• Quality results
• Shift handover report

Preferred candidate profile

Education - Diploma/ BE (Mechanical)
Experience - 4-6 years of relevant experience
Product knowledge- Gypsum / Cement
Behavioural Competencies - Ownership & Accountability, Learning Agility, Problem Solving &