DH Reliability CRM & FL

3) Job Context & Major Challenges:

Job Context:

The FRP of Hindalco Industries Limited at Hirakud has a Hot Mill a Cold Mill and a set of Finishing Lines operating as self-contained units handling both operations and maintenance supported by a Central Engineering function and Planning and Warehouse function as well as Human Resources IT and Finance comprising Accounts Purchase and Commercial functions.

Finishing Lines consists of Danieli Slitter Sundwig Slitter Tension Leveler and Cut To Length along with Coil Packing Line and Sheet Packing Line. Finishing Lines have combination of old and new machines and is the last part of operation of Hirakud FRP after Cold Mill Process from where the Products goes to customers.

The finishing lines process coils to achieve specifications such as customer specified width and weight of coil. They are also required to ensure that the surface defects along with gauge variations from upstream processes like Hot Mill and Cold Mill are detected so that customer is not affected. Along with detection of upstream defects finishing line also required to ensure that defects are not generated in finishing lines.

Finishing line equipment are the widest and biggest in terms of production and specifications amongst downstream units of Hindalco. Danieli Slitter has the capability to process coils of gauge ranging from 0.1mm to 2.5mm of coil weight upto 20MT. Danieli Slitter is the only slitting unit in India with Post Lub facility to process Can Body Stock Coils. It has CNC operated Center slitting unit. Cut To Length is also the widest sheet making line of Hindalco with processing capability of 6000mm/2000mm size capability. Cut To Length has one of its kind 3-High Sheet Leveling Unit along with one-of-its-kind automated vacuum stacker and CNC operated trimmer unit to process coil gauge ranging from 0.4mm to 4.0mm. Apart from the above 2 new machines Tension Leveler is the old machine upgraded to process tension leveled aluminium coils. The coil gauge ranges from 0.4mm to 4mm and process width ranges from 900mm to 1700mm. Being an old machine various upgradations and revamping are being carried out to enable processing of tensioned levelled export coils. 99% of the export coil products are processed through Tension Leveler. Sundwig Slitter is also an old equipment with capacity of processing coils of gauge ranging from 0.1mm to 2.5mm. The finishing lines are attached to Coil Packing Line and Sheet Packing Lines are latest equipment with automatic packing operations.

This role is responsible for ensuring condition based monitoring of equipment across the Finishing Line which constitutes of 2 nos. Slitting lines 1 no. Cut to Length lines 1no. Tension Leveler line 1 no. automatic Sheet Packing line and 1 no. automatic coil packing line and improvement of reliability of equipment through implementation of CBM action plan in collaborationwith the maintenance team for planning and execution of approved work orders. It involves data analysis of all machine and process parameters. Monitoring reliability KPIs to reduce MTBF (Mean time between failures) and improve uptime.

The role is required to collaborate closely with other functions such as process and maintenance as well as central reliability cell for upgradation and removal of bottlenecks to improve life of the equipment.This includes shutdown coordination. Criticality is to ensure continuous availability of equipment and improve total life and health of equipment.

Another critical aspect of the role is upgradation of equipment and process control for new product development as per organisational need. It also involves reducing equipment cost.

The role is required to continuously benchmark best practices as per Novelis standard and prepare the roadmap for reliability.

An important aspect of the role is to impart training to upgrade technical knowledge and safety awareness to minimise harm and prolong asset life.

This role is also responsible for guiding the teams under jurisdiction in maintenance of health safety environment norms and statutory norms. Criticality is complying to stringent pollution control norms with focus on maintaining stack emission to ensure zero discharge of solid particles and safety of rotating equipment

Job Challenges:

1. Unionised workforce
2. Combination of Old & New Equipment
3. Sourcing spare parts and developing skills in the backward location of the plant for the gigantic equipment unique in India

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

1. Business Excellence

• Supervisingcontinuous equipment availability at the Finishing Line through reliability testing and giving inputs to maintenance and operations teams in preventive and predictive maintenance and overhaulingduring shutdown
• Implementing Standard Maintenance Practices.
• Monitor and Track Nonconformities because of Engineering issues every day and do root cause analysis and take corrective actions to reduce the NCs.
• Resolve Engineering Issues promptly impacting Equipment Reliability

1. Cost

• Giving inputs for planning and budgeting with respect to CAPEX and R&M for the next financial year as well as monitoring implementation with respect to the Finishing Line machinery
• Implementingcost saving by driving continuous process improvement without compromising quality

1. Cash

• Monitoring inventory of spares in order to optimize working capital and improve profitability and cash flows

1. Customer

• Supervising CBM across the Finishing Line in every shift in order to minimise MTBF to meet customer expectations
• Minimisingresponse time in providing information and solutions to all internal and external customers

1. Sustainability & Compliance

• Implementing compliance of all statutory and environmental norms with focus on environmental guidelines of PSPCB/CPSB
• SupervisingWCM Kaizen and improvement projects for continuous improvement and greater sustainability
• Supervisingg good housekeeping practices and green initiatives in area under jurisdiction
• Timely Execution of capex project for modification & improvement activities for FL equipment.

1. Safety

• Monitoring implementation of safety through Monitoring implementation of HIRA JSA LOTOTO and work permit systems
• Facilitating safety related training to own and contractual teams to embed a safety culture as per standardsand achieving zero incident
• Implementing emergency handling readiness through continuous review and course correction

1. People development and engagement

• Facilitating on-time recruitment for vacant positions
• Monitoring and improving performance of team members
• Facilitatingcompetency building and multiskillingthrough training need identification training initiatives to enhance technical and behavioral competencies towards greater productivity
• Monitoring intake and deployment of appropriately trained contractual workforce in area under jurisdiction and ensuring their continuous training and wellbeing as per company guidelines.