Support DMT Mbr Ops 3, Dahej

Job Description 1) Job Purpose - To achieve targeted production of copper within stipulated purity range, budgeted cost and time frame through efficient operation of Anode Furnace and Anode Caster -To ensure compliance of all quality, safety, health, environment, hygiene parameters and statutory compliances through strict monitoring of operations, process control and improvement.2) Dimensions: Business/SBU/Unit Revenue 50000/35000/15000 cr. Business Workforce Number Unit Workforce Number Function Workforce Number Department Workforce Number Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameterCopper Anode Production- 225000 T Job Context: Birla Copper unit at Dahej is a copper smelting operation having two operational copper smelters to process blended copper concentrates of varying specifications to supply copper in the form of anodes of 99.5% purity to the refineries attached to them. This position is responsible for the operation of 3 numbers of anode furnaces, Anode caster having 2 numbers of cast wheel , Caster Cooling Tower, Anode off gas fan, Oxidation duct, Reduction duct, one number of EOT 50 MT crane, two number of EOT 10MT crane , DOC burner of furnaces and ensuring maintenance as per schedule. The operation involves hazardous processes and generation of corrosive and toxic intermediate products which need to be monitored to be able to keep emissions such as SO2, dust within permissible limits. The role involves strict compliance of statutory stipulations and compliance of quality, safety, health and environment parameters as well as energy conservation in area under jurisdiction during the assigned shift.Key aspects of this role are analyzing and understanding the anode furnace operation, Cycle time, Charging solid pure anodes, Blister receiving quantities. Optimizing anodes chemical properties and molar ratio (by charging external scrap, internal scrap and Lib cake and by doing slagging ) Ensuring physical quality of anode as per requirement of Refineries. (planning mold cast, Mold levelling, replacement of ejector pin etc)Ensuring availability of Solid charges and liquidation of both External and Internal Scrap Maintaining Cooling Tower water quality. Maintaining availability of EOT crane, All anode furnaces and Caster. Coordinate with MI SI for change over, Gas diversion (During Receiving blister, peroxidation and Oxidation gas divert to SAP plant and During Reduction Gas divert to Dryer or stack.)Coordinate with Both Refinery SI for anode dispatch, improvement of quality, Anode wt and issuing Scrap. Coordinate with External Yard SI for issuing External scrap and from CCR for issuing rej cu bearing material. Coordinate with Service department for maintenance or attending breakdown of equipment in Shift.Major challenges: The continuously changing raw material (copper concentrate) profile and varying quality results in fluctuation in of blister flow in anode furnaces Maintaining different furnaces cycle time Maintaining and monitor Life cycle of Blister Tip Monitor anode furnaces Skin temperature.Availability of cranes for Solid charging, Slagging, Replacement of Launder, Spoon , Intermediate ladle, Anode lifting, Mold casting, Mold replacement etc. Plant is old and needs upliftment, making achieving plant uptime a challenge. Process is hazardous with corrosive, toxic emissions, minimizing emissions within PCB norms and meeting other environmental and safety norms difficult.To do the gap analysis for the power, fuel and oxygen consumption with the budgeted consumption and look out for the ways to bring them back within budget. To plan&utilize daily casting wheel preparation, mold levelling, mold casting to maintain anode physical quality as per refinery demand. To ensure the right consumables quality and quantity is available by maintaining the agreed stocks levels at shop floor. Barium sulphate consumption reduction, Environment compliancesMock drill participation Enablon, NM, PI, UC&UA as per corporate guideline Provide equipment for maintenance without affecting daily production target. Archive daily production target by maintaining cycle time of anode and charging solid scrap. 4) Key Result Areas/Accountabilities: Key Result Areas/Accountabilities Supporting ActionsProduction To deliver required Copper Anode production with quality as per refinery requirements and P&B. Manage the operations of Anode Furnace and Anode Caster Review to ensure no deviations in processe Ensuring quality of as per Refinery demand. Giving handover with inputs at the end of the assigned shift with respect tothe production cycle of anode furnace, charging in anode furnaces and casting status.Planning shift operations in line with the production plan at the beginning of the assigned shift Cost To be cost efficient Ensure PBU budgeting (Capex&Operating) cons Ensuring achievement of cost saving without compromising quality and delivery by driving cost-saving initiatives, other major initiatives for reducing production costs and de-bottlenecking. Cash To improve working capital To ensure store inventory is under control and within the P&B limits. Ensure execution and utilization of cash flows for Capex projects as per plan. Customer Centricity Fulfil internal&external customer expectations for satisfaction and reliability, cost, and delivery Ensuring meeting Internal of customer expectations by honouring service level agreements (SLA) Ensure implementation of the action plan as per feedback from internal customer satisfaction surveys. Collaborate with the customer and COE-Process Care to ensure the supply of quality products within the limitations of varied raw material quality.Ensure Customer Relationship Management through PST and customer-supplier meetings Drive customer centricity as a culture in the team Managing and monitoring the contracts and relations with customers, vendors, partners, and other stakeholders as per regulation Sustainability&Compliance Develop and implement the roadmap for sustainable practices Ensuring compliance with all statutory and environmental norms in PBU. To develop a roadmap for achieving plant/ business aspirations and ensure its implementation for short-term and long-term sustenance. To develop Heat Map, prioritize the areas for improvement and ensure its implementation as per plan.Ensuring compliance with statutory norms and HIL standards for Occupational Health, safety, and environment etc. Controlling and maintaining the discharge of pollutants as per statutory norms&adhere to ZLD plans for all units of Copper 3 PBU. Safety, Health, and Environment To ensure zero harm by building a culture for safety and valuing Human Lives Embedding a safety cultureby spreading awareness to build a safety culture, implementing safety standards, developing safety mechanisms, and ensuring safety-related training is imparted to achieve zero harm by working in close coordination with all stakeholders.Ensuring emergency handling readiness of all cross-afunctional teams across the PBU. To create a safe work environment by designing/re-engineering/Continuous Improvements. People development and engagement Building Capabilities of Employees and enforcing a culture for people development and sustainabilityEnsuring all people development processes driven by the business are implemented in the PBU Monitoring intake and deployment of the appropriately trainedcontractual workforce and ensuring their continuous training and well-being as per company guidelines Monitoring and improving the performance of team members.Driving interdepartmental mobility through multiskilling. To motivate and ensure engagement and involvement of all team members with enhanced morale. 5) Role Specific Competencies Technical competencies Degree in Metallurgy with adequate relevant&troubleshooting experience in Anode furnace, Anode caster, Utility and Scrap management Troubleshooting of AF, AC , Cooling Tower, Utility Behavioural competencies ABG Leadership Competencies