-
To Ensure Electrical and Instrumentation maintenance in three shift operation of DC-3 & DC-4 & to ensure their reliability and continuous availability towards smooth operation of DC-3 & DC-4.
-
Electrical Isolation of 415V and up to 11KV voltage level as per statutory guideline.
-
Strictly follow PTW, LOTOTO, HIRA, JSA, SMP and all safety standards of M/S HIL.
-
To continuously facilitate upgradation skills of the team and embed a culture of quality, safety, and sustainability.
-
Review daily work orders, ensure compilation & provide reports.
-
Participating in equipment improvement plans using historical data on breakdowns as the tool, capturing and tracking actions to completion.
-
Reporting on down time and entering this data into the MIS and logbook.
-
Thorough knowledge of all applicable policies, rules, regulations, and codes, in a specific engineering field.
-
Modification to existing controls for improved process control, reliability, safety, and compliances with OSHA requirements.
-
Develop & maintain good working relationship with production team to formulate the best cost-effective manufacturing process and present a good image of the E&I.
-
Recommend replacement for old or faulty electrical equipment to the management
-
Keep record of all stock and supplies, store items & inventory control.
-
Support the company in increasing profitability by managing resources efficiently and making necessary recommendations.
Job Context & Major Challenges:
The Smelter of the Aluminium Production Unit of Hindalco Industries Limited at Hirakud has a Potroom, a rodding plant with a carbon unit, and Cast houses. Molten aluminium is tapped out in ladles and supplied to cast houses where they are cast into Rolling Ingots, Cast Coils, pig ingots as well as Sow Ingots, utilizing entire liquid metal & Aluminium scrap from FRP. The products of Cast House are supplied to downstream plants of Hindalco or directly to external customers.
Hirakud has two cast houses, with state-of-the-art facilities and linked to dedicated downstream Hirakud FRP as stated below.
DC3- It produces mainly hard alloys for heavy duty application & supply to Hirakud FRP for export and domestic market.
It also produces Pig Ingot through ICM as per market requirement.
DC4- It is latest cast house with state of art equipment compatible with requirements of the export & domestic markets. It produces ingots for Hirakud FRP, Belur unit, Mouda unit and supplies the same directly to the concerned unit.
This involves collaboration with other maintenance teams forDC3 &DC4 plant availability and with the commercial and support functions for resource availability. Critical aspect is to embed right blend of maintenance practices such as preventive, predictive and reliability centred maintenance, breakdown maintenance as and when required as well as planned shutdown and overhauling
This role ensures all statutory compliances related to health, safety, energy and environment. This role is also required to focus on continuous improvement through capability building,
improvement initiatives, performance monitoring as well as improvement of efficiency parameters, quality, safety and sustainability.
4) Key Result Areas/Accountabilities:
Key Result Areas/Accountabilities
Supporting Actions
-
Ensuring continuous equipment availability at DC3 &DC4 through preventive, predictive, breakdown maintenance as well as shutdown and overhauling with respect to electrical aspects of the equipment
-
Undertaking maintenance planning in oracle system and data monitoring through breakdown analysis and control, root cause analysis (RCA) and corrective and preventive action (CAPA)
-
Formulation of standard maintenance practices as well as reviewing and monitoring implementation of the same in all aspects of maintenance under jurisdiction
-
Planning and budgeting with respect to CAPEX and R&M for the next financial year as well as monitoring implementation with respect to the cast house
-
Awarding annual job contract for maintenance and service at the best possible rates
-
Partnering planning and budgeting with respect to all technical upgradation and regular maintenance for the next financial year
-
Implementing budget through strategic planning of Electrical & Instrumentation maintenance activities
-
Partnering in alternate vendor development and ensuring reduction in rework
-
Achieving cost saving without compromising delivery by driving continuous process improvement across area of operation
-
Optimizing inventory of spares and consumables so as to optimize working capital and improve profitability and cash flows
-
Improving profitability through spare part substitution where OEMs are closed and the cost of replacement is high
-
Partnering cost projections for working capital and cash flow management for the next financial year with respect to area of operations
-
Contribute to profitability through optimizing working capital by reducing the cost of maintenance by developing internal resources for testing and calibration, maintenance of optimum spares inventory and eliminating breakdown
-
Reducing meantime to repair (MTTR) and improving the meantime between failures (MTBF) in order to maximize internal customer satisfaction.
-
Partnering commercial teams in vendor development.
-
Ensuring response time in providing information and solutions to all internal and external customers is minimized
-
Ensuring execution of breakdown maintenance activities with minimum downtime
-
Reviewing and monitoring maintenance of critical spares having longer lead time of procurement.
-
Sustainability & Compliance
-
Driving WCM, Kaizen and improvement projects for continuous improvement and greater sustainability
-
Ensuring good housekeeping practices in area of operation
-
Leads energy saving initiatives
-
Ensuring compliance of Integrated Management system and Energy Management System
-
Partnering in green initiatives:
-
Maintaining of instrumentation equipment to achieve reliability and availability of pollution control equipment to maintain environmental norms.
-
Ensuring ISO 45001, ISO 50001 or any other energy of safety management certification compliance
-
Implementing Safety standards and developing safety mechanism to achieve zero reported incident
-
Ensuring a culture of safety as per standards through actively participating in safety walk downs and monthly celebration of lack of incident to embed safety culture
-
Reviewing and monitoring implementation of Health, Safety, Environment norms in area of operation:
-
Implementation of safety standards such as LOTOTO, MSDS, 5S
-
OHSAS standards & compliance
-
fire safety mechanism
-
HAZOP study
-
Risk assessment
-
HIRA.
-
Compliance of all safety observation &implementation of safety task forces to eliminate unsafe behaviour.
-
Ensuring safety related training is imparted to all sections of Electrical & Instrumentation maintenance teams including contractual workmen
-
Undertaking Consequence Management.
-
Ensuring emergency handling readiness through continuous recording of special events, failure analysis, efficiency improvement, benchmarking, efficiency evaluation
-
People development and engagement
-
Monitoring and improving performance of team members
-
Ensuring competency building through training need identification, training initiatives to enhance technical and behavioural competencies
-
Driving mobility across various sections of Instrumentation maintenance team through multiskilling
-
Improving team engagement scores
-
Monitoring intake and deployment of appropriately trained contractual workforce and ensuring their continuous training and wellbeing as per company guidelines.
-
Implementing digitization and digitalization projects - leading upgradation of PLC and SCADA system to mitigate obsolescence.
