FLO Instrumentation
- Gujarat
- Permanent
- Full-time
Complete plant instrumentation ISO.
SAP asset management.
To maintain & up grade plant communication system such as Public Addressing System & Radio System.
Data transfer of Spinning to historian. Network & communication to historian with IT Team.
Maintain the Inventory to run the plant. To keep the cost to maintain the budget.
Implementation of scheme within time & budget.
Up gradation of Instrumentation within time & budget.
Up gradation of plant Control system.
To ensure safety in all the activity of the plant.
To meet all the required environment & safety related measurement & control in the plant.Job Context & Major ChallengesBirla Cellulosic is a Green Field Project of Grasim Industries Ltd. The project was conceptualized in the year 1994 and was fully commissioned in 1998. The unit has an installed capacity of 350 TPD of Viscose Staple Fiber and is the most modern Viscose Staple Fiber producing unit of Grasim As pulp & Fiber business, with its four manufacturing streams of Viscose Staple Fiber of 350 TPD, 65TPD Carbon di Sulphide (CS2), 350 TPD of Sulphuric Acid, 40 MW Thermal Power Plant and other auxiliary plants like Water Treatment, Demineralization & Effluent Treatment Plant etc. Grasim As pulp & fiber business has grown over a period of last 50 years and has matured in terms of cost, quality & productivity. Today Grasim As Viscose fiber is branded as `Birla Viscose and is considered as most environment friendly textile grade viscose fiber known for its feel & comfort. Birla Cellulosic As plant was put up to further strengthen the groups market leadership in the fiber business and expand its share in the world market by producing best quality product. With the vision of making the plant a world reference point in terms of quality the project was provided with most modern state of art machinery & instrumentation. The process of Viscose Staple Fiber is a continuous chemical process & the accurate process control is achieved by most modern distributed controls & programmable logic controls. High level of automation eliminates human error and ensures trouble free operation of the process. Thus instrumentation and controls play a key role in ensuring best product quality & productivity of operations.
The major challenges for the position are :-
1. Maintain Automation and Packaged system Instrumentation. 2. Competitors are more aggressive for Product quality and quantity. Thus there is need of consistence productivities and quality to satisfy customers need.
3. Focus on Maintenance cost reduction and Energy conservation. 4. Focus on unplanned down time, reduction in inventory. 5. Betterment of Instrumentation & Automation system to ensure safety.
6. Non availability of machines for maintenance due to continuous running of process
7. Highly Corrosive environment leading to high level of corrosion of electronic cards, resulting in higher failure rate.
8. Spinning Machine & After treatment Sequence Logic complexity to understand & resolve issue.
9. Dryer Machine Sequence Logic complexity to understand & resolve issue.
10. Auto Fibre Packing system Baler & Fine opener troubleshooting complexity
11. Auto Bale Conveying system - ITW troubleshooting complexity
12.Forte Fibre Measurement System troubleshooting complexity
13. Up gradation of system in rapidly changing development field of process Control & Instrumentation.
14. Ensuring smooth operation of instrumentation and control system to maximize availability of process control loops for smooth operation of the process.
15. Ensuring availability of critical spares within budgeted frame of maintenance without effecting productivity and maintaining quality norms.Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)
KRA1 Delivery & Innovation activities 1. Ensure round the clock availability of Instrumentation and control system in Spinning section and provide information for remote accessibility of critical parameters to customers to enhance plant performance for quick and prompt decisions to meet process target.
2. Monitor Regular implementation of PM schedules for reliability and availability of instruments.
3. Regular monitoring of daily checklist & ensure availability of instrumentation by taking corrective actions.
4. Calculate MTTR & take corrective steps for continuous improvements. Monitor & Improve MTBF by using improvement tools & systems.
5. Coordinate timely completion of logic modifications in Distributed Control System.
6. List of current spares to be updated regularly for easy access at budgeting stage of the schemes.
7. Scheduled training to shift technicians. Standard trouble shooting procedures.
8. Updating Hardware as well as Software documents for easy access at the time of breakdown.
KRA2 Productivity:
Monitor & coordinate maintenance activities of VSF plant so as to achieve optimum production loss & delivery within target cost & quality Parameters. 1. Ensure the availability of instrument system to meet the manufacturing targets and other customer requirements
2. Preventive Maintenance Schedule preparation & Evaluation
3. Predictive Maintenance Check list preparation & Evaluation
4. Breakdown maintenance job Execution & guidance to subordinate
5. RCA & Why-Why Analysis to avoid repeated problem
6. Health Monitoring of Instrument through AMC-DCS
7. Shutdown Activity execution & co-ordination with process team
8. Review customer complaints and take relevant corrective action
9. Focus on Reduction in Unplanned Instrument Downtime
10. Upkeep the Fiber Packing system to meet manufacturing targets
11. Upkeep the Bale Conveying system to meet manufacturing targets
12. Upkeep the Fiber Moisture measurement System to meet manufacturing targets
13. Upkeep the Jet Cleaning System to meet manufacturing targets
KRA3 Control System maintenance :
To ensure continuous DCS support & trouble shooting 1. Ensure the availability of control system to meet the manufacturing targets and other customer requirements
2. Health monitoring & corrective action to maintain uptime of Controller , I/O cards & operator work station
3. Ensure closed loop controlling by monitoring final control element function & tuning parameter setting
4. Sequence operation troubleshooting to run batch process smoothly
5. Control system Preventive Maintenance Schedule preparation & Evaluation
6. Ensure PLC system availability by maintain Grounding & power supply within limit
KRA4 Modification/Improvement Projects : To suggest the modification / improvement projects to improve quality & productivity 1. Ensure product development and plant up gradation to ensure long term liability
2. Introduce technological change for improved Quality, GMP & Safety with cost effectiveness.
3. MOC preparation /evaluation for change management process
4. DCS logic modification for quality & productivity improvement as per process requirement
5. Provide the services & equipment needed for new products and formulation changes
6. Identify/Evaluation of KAIZEN for implementation
7. Working upon cost estimation of small modification & improvement project & its proposal making
KRA5 Spare Management & Cost optimization :
Planning & Monitoring spares management to ensure better cost optimization. 1. Identifying and procuring the required equipment spares and accessories by proper planning and follow up inspecting and accepting the incoming materials with respect to indents raised.
2. Maintaining BOM for Instrument apparatus
3. Procuring required materials by floating enquiries, conducting techno-commercial comparison , dealing with vendors & so on
4. Prepare yearly budgets and Work services to meet targeted requirements and controls.
5. Review budget & Inventory Control by spare material criticality analysis
6. Ensure Maintenance contract are awarded only for special Instrument, rest all activities carried out by utilizing in-house resources
7. Ensure resource management for day to day & shutdown activity
KRA6 People Development:
To enhance knowledge & skills of team/subordinates. 1. Identifying training needs, Skill gap & recommendation for skill improvement
2. Development of maintenance team by structural training & job coaching
3. Train the workforce for safe practices & technical subject for maintain the control system to meet all the environment standard
4. Appraise, Inspires & stimulate subordinate to maximize their performance towards department goals
5. Developing team work culture
KRA7 Quality 1. Execution of all preventive Maintenance schedule, timely completion of all schemes with in its stipulated budget & given time frame in assigned area.
2. Monitor Regular implementation of PM schedules for reliability and availability of instruments.
3. Regular monitoring of daily checklist. Develop suitable control logic in consultation with process department.
4. Implementation of new schemes as and when required and ensures optimum utilization of resources.
5. Daily coordination meeting with in department.
6. Generate Item code for new procurement. Maintain minimum inventory of critical spares.
7. Organize repair/rectification of the defective instruments wherever applicable.
8. Ensure 100% availability of all communication equipment's. Immediate response to any complaint or breakdown
KRA8 System Management 1. Ensure implementation of QMS/EMS, World Class Manufacturing (WCM) SC & other TPM / TQM initiatives.
2. Enhance the working of allotted SC working in the department improve the monthly score.
3. Take corrective steps for effective implementation of WCM sub committee.
4. Implement recommendations of audit & close non-compliances.
5. Review of proper filling of history sheets and calibration sheets.
KRA9 Safety & Statutory compliance :
To plan the various safety initiatives to create safe working condition & also meet the statutory compliances. 1. Critical Instrument Calibration frequency finalize, Schedule preparation & Evaluation
2. Ensure that all Calibration activities are completed within the due date and all the SOPs are current and are in use by the concerned person
3. Updating & Maintaining documentation related to projects like user requirement specification, installation, operational & performance qualification
4. Ensure timely review of IMS, WCM, process safety documents to meet the respective standard requirements
5. Review of Policies ,readiness for internal & external audit compliance
6. Identify department HIRA , ASPECT-IMPACT & ensure implementation
7. Provide measurement & control to meet the statutory & legal requirements.
8. Six step Safety Observation process follow-up as per schedule
9. Betterment of Instrument System to Ensure Safety
10. Ensure safety practices implementation within team
11. Activities are to be carried out adhering to safety norms to ensure safety of equipment & personnel. Monitor safety procedures & implement safety requirement in working. Providing Safety trainings & DCS interlock awareness Training.