To Ensure the availability of Tippers & Tip trailers to meet the targeted Limestone production on daily basis, monitor the budget, inventory and MTBF/MTTR to achieve the Departmental objectives.
Job Context: Andhra Pradesh Cement Works (APCW) : a unit of UltraTech Cement Limited, a flagship company of the Aditya Birla Group is situated at Tadipatri, District - Anantapur. APCW has 2 Lines. Line-1 was commissioned in 1998 with an installed capacity of 2 million tons (2 MTPA) cement annually, which has been enhanced to 2.7 MTPA over a period of six years through several improvements and modifications. Line-2 was commissioned in August 2008 with an installed capacity of 3.4 MTPA. The total cement production capacity of APCW, along with the associated Units, is 11 MTPA. The integrated plant is associated with two grinding units and one bulk terminal - Arakkonam Grinding Unit (ARCW) in Tamil Nadu, Ginigera Grinding Unit (GICW) in Karnataka and Shankarapalli Bulk Terminal (SBT) in Hyderabad. The unit has also established a thermal power plant of 2 X 25 MW capacity to cater the plant's power requirement.
The APCW Mine is located near Tummalapenta Village, Kolimigundla Mandal, Kurnool District at Andhra Pradesh. It has a production capacity of 9.20 MTPA. The mine lease extents up to 844.939 hector. It was opened in the year July 1997. The general geology falls in Narji Limestone formation of Kurnool system, age of 800 Mio years old. As per UNFC classification, mine has got the limestone reserves of 181.65 Mio MT as on 31 March 2012. Winner of the prestigious National Environment FIMI Award for the year 2002-03, it is one of the largest mines producing 9.20 Mio MTPA limestone at single location
Major Challenges:
To improve the competency level of operators and mechanics.
Reducing cost of maintenance and breakdown of Tippers
To save fuel (Diesel) & Lube and consumption of spares and reduce breakdowns of HEMM a ageing equipments
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1
SHE (Safety, Health & Environment) along with Sustainability initiatives
Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.
Educating team about “I know my job”, “I know the hazards associated with my job and I applied control measures” & “I escalate to my senior” among manpower deployed in sections/department manpower including peer, WB & CL manpower
Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
Active participation in safety training, safety sub committees, standard champions meeting and any safety event
Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
Adhering of all safety precautions on the site and off the site
Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.
KRA2
System Implementation
To implement improvement project to reduce repetitive problems/breakdown or losses.
Timely submission of Kaizen, OPL, Good to fine, suggestion on system
Developing and sustaining Model area in respective sections
100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programmes down the level team
To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
Implementation of critical spares & consumable SOP without any defilement
Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.
Preparation of DPR report, MIS, M2 and M4 Notification in SAP on shift basis.
Responsible to update QCDIP & LCM.
KRA3
100% compliance of Statutory and maintaining records
Completion of all statutory recors timely for equipments
Air receiver test, Brake test, Pollution test etc.
To comply with the applicable statutes
KRA4
Cost Control:
(Assist superior to control maintenance costs of HEMM, LMV, Cranes etc, to optimise cost of operation and maintenance.)
To reduce the invetory of tippers as part of cost control exercise.
Inventory analysis using various methods (VED, XYZ, FSN, etc)
To reduce the HSD consumption on total material handling as part of cost control exercise.
Engine, FIP & injectors overhauls and effective maintenance techniques in a phased manner.
Control contractor & over time cost.
Better maintenance practices through PM analysis or Why Why analysis.
Monitor fuel and lubricant consumption.
Standardisation of the equipment to maintain low inventory.
Introduction of fuel efficient equipment (engines) Enhance the life of the major sub-assemblies by quality maintenance.
Life value analysis.
KRA5
Availability of Heavy Equipments for Mines Operations
To ensure equipment availability as per targets.
Proper planning of spare parts & scheduled maintenance based on OEM recommendations and also conditioned based monitoring.
To reduce the breakdown of equipment to ensure availability for operation
To improve MTBF & MTTR
Monitor preventive maintenance schedule.
Liase with stores for spare parts availability.
Monitor stock availability of fuel and lubricants
Utilisation of SAP/R-3 PM (Module) for history data.
Take steps for upgrading of existing equipment.
Interact with OEM for major problem & improvement.
To save fuel (Diesel) & Lube and consumption of spares and reduce breakdowns of HEMM equipments.
