General Manager To Vice President - Mechanical Cement Manufacturing.

Job Description

RESPONSIBILITIES: MECHANICAL - MAINTENANCE & OPERATION

• All types of Maintenance OF CEMENT PLANT (i.e. Pro-active, Break-downs, shutdowns and preventive & condition monitoring) of the LIMESTONE CRUSHER, STACKER & RECLAIMER, BALL MILLS FOR COAL, LIMESTONE & CLINKER GRINDING, VRMs FOR CEMENT, COAL AND RAW MILL, KILN, GRATE/CROSS BAR/CFG CLINKER COOLER, CEMENT PACKING PLANT SYSTEM & Clinker & Coal transport system.
• 24x7 Works in a manufacturing plant environment with possible exposer to dusty, loud, hot or cold, and changing environments.
• Directly supervises maintenance supervisors and engineering staff, with next-level maintenance employees reporting through supervisors.
• Major/minor Shutdown planning as per the requirement of plant and management.
• Plant availability and cost control.
• Cost reduction in spares and consumables
• Harmonious Coordination with the process, instrument, and electrical people to enhance productivity.
• Skilled Upward & downward reporting.
• Team development by giving internal training down the line/sub-ordinates.
• Reduction in energy {power & fuel}, lubrication & hydraulic oil & spare consumption.
• Hydraulic & Pneumatic circuit maintenance.
• Condition-based Preventive Maintenance System.
• Material management, Indenting, Inventory control, Standardization, and Waste control.
• Project planning, layout, execution, and scheduling.
• Manpower management
• Emission level control under factory act & norms.
• To plan shutdown jobs and materials in such a way so that plant availability may increase.
• Follow-up with purchase Dept. / Supplier.
• Prepares and monitors Budget for adherence of the departments.
• Spare parts planning and inventory control.
• ISO documentation.
• Ensuring compliance with internal safety norms.

Shutdown Maintenance for three Kiln lines, starting from Lime Stone Crusher to Clinker Stoke Pile.

• Responsible for Resource Management of Kiln Shutdowns, related to all stakeholders, i.e. Mechanical, Production, E&I, Civil, and other auxiliary departments.
• Responsible to manage and execute all 5 phases of Kiln shutdown as per LH guideline (i.e. Planning, Scheduling, Preparation, Execution, and Analysis & Learnings)
• Responsible to complete the shutdown within the planned budget and analyzing to reduce the shutdown cost and duration by brainstorming and implementation various best practices.
• Preparation of shutdown budget in terms of shutdown days and cost.
• Planning and execution of shell and major component replacement activities related to all three Kilns with updated history records.

Maintenance Cost Budgeting

• Responsible for Maintenance cost Budgeting (All three Lines from Crusher to Packing Plant)
• Preparation of annual maintenance cost budget
• Ensure Execution of all maintenance activities within the approved budget by tracking cost every month
• Responsible for implementation of various new maintenance management projects initiated by LH.

Capex Planning

• Responsible for Capex budget finalization for Maintenance Activities.
• Responsible for Maintenance Capex planning and completion within the approved budget and timeline
• Monthly/Weekly maintenance CAPEX tracking and reporting
• All modification and rectification work during erection of equipment. Replacement of bearings of coal mill VRM supplied by Gebr. Pfeiffer, Germany had been executed under my supervision.
• Planning effective manpower deployment for erection/commissioning works and addressing the training of staff to enhance skills and productivity.
• Planning of day to day erection activities, achieving weekly and monthly targets, and coordination with contractors for achieving the same.
• Indenting of spares through SAP and inventory control. Preservation of all spares.
• Maximum utilization of men, equipment, and resources.
• Troubleshooting daily technical problems and doing Root Cause Analysis of chronic problems

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Keyskills :
maintenance activitiesroot cause analysisltdresource managementequipment supplymaintenance managementpreventive maintenancecoaldeliveryproject managementroot causecost controlautomationinventory controlcontinuous improvement facilitationsap