MT ELP

Designation: Assistant Manager

Location: India Madhya Pradesh Maihar Cement Works

Organization: Cement

Job Description:

Job Context: - UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The Company has a consolidated capacity of 137.85 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals.

Maihar Cement Works is a modern cement plant with a high level of automation, computer-aided data acquisition & sophisticated control system, which ensures quality at every stage of production. The Unit is strategically located at Sarlanagar at a distance of about 8 Kms from the town of Maihar on Maihar-Dhanwahi Road in Satna District of Madhya Pradesh. About 45 Kms South-East of Satna, a hub of Cement Industries in India. Maihar is situated at the Main Railway line of Howrah-Mumbai. It is one of the famous dots in the mythological map of India and also regarded as the abode of Goddess Sharda.

The Unit has a clinker production capacity of 3.0 MTPA, Cement Production capacity of 4.2 MTPA & manufactures OPC 43, OPC 53 & PPC grade of cement with Environment clearance for cement production capacity enhancement to 6.0 MTPA. Unit also has a solar power plant of installed capacity 12.5 MW DC / 8.75 MW AC and is equipped with the latest technology & equipment’s. The Normal Power requirement of the Unit is about 47.5 MW which is being met through our two nos. TPP of a total capacity of 2 x 15.7 MW. We have also a contract demand of 22 MVA with MPPKVVCL.

There are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff ColonyThere are four townships (Staff Colony, Bank Colony, Juda Nala Colony and Mines Colony) adjacent to plant with facilities like 30 room guesthouse, sports & recreation club with swimming pool, temple, 30 bedded Hospital, garden, playground, children park, etc. Unit also facilitate CBSE Affiliated School within colony premises and College about 500 mtr from Staff Colony.

Today, unit is acknowledged as one of the most efficient, vibrant, productive, profitable, technologically updated and state-of-the-art unit of Aditya Birla Group’s UltraTech Cement Business.

The focus area for Job holder is to ensure water supply availability in plant and colony and handling the Mechanical Utilities operations including workshop for supporting plant in achieving budgeted production targets within defined quality, cost and safety parameters. The position is also responsible for providing timely and accurate information to Management for taking strategic decisions, co-ordination with other technical, commercial, HR and Mines departments for day to day operations and effective planning of plant operations.

Major Challenges:

Maihar is an over 40 years old plant with Line 3 installed in 1985 this possess a challenge of upgradation of existing major equipment and processes to increase the Plant output and key parameters. Few challenges due to this area (a) High Specific energy consumption due to old technology (b) Multiple Equipment’s with less TPH required extensive maintenance however Specific maintenance cost need be competitive with internal benchmarks.

Ensuring continuous plant operations and also space constraints makes it challenging for execution of upgradation / modification jobs taken up for productivity improvement in the plant.

Most of the employees are from Ex CTIL era especially in WB and CL and require regular hand holding, training and support in delivering to UTCL system and processes like Safety, Internal / External Audit, Elimination of MUDA , ABOE framework implementation etc.

To optimize operations to achieve better business results in power consumption, fuel consumption and fly ash consumptions.

Multiple locations of installation of critical equipment like Crusher which is situated in Mines at about 8 kms from plant and there are 2 conveyor belts for feeding material to plant which are 6 kms long.