Aditya Birla Chemicals Hiring for Engineer-Mechanical Maintenance (Caustic) at Karwar, Karnataka, India Full Time

Implement maintenance activities of Caustic Soda plant so as to maximize plant availability at minimum maintenance cost while also maintaining safety & environmental standard with available resources to meet production targets

Job Context & Major Challenges

There are Seven Units of ABG in India manufacturing Chlor-Alkali products: Grasim Chemical Division Nagda (M.P.), Grasim Chemicals Vilayat (Gujarat) Grasim Chemicals Veraval (Gujarat) Grasim Chemicals Gharwa Road (Jharkhand), Grasim Chemicals Renukoot (UP), Grasim Chemicals Karwar (Karnataka) & Grasim Chemicals Ganjam (Orissa). ABG Chlor-Alkali Business (India) is headed by SBU Head.

The Unit Grasim Industries Limited Chemical Division Karwar Facility operates Phosphoric Acid manufacturing plant of 24000TPA & 59400TPA Chlor Alkali Chemicals Plant with Mercury Cell Technology in the name of Solaris Chemtech since 1975. For implementing CREP Recommendations for Chlor – Alkali Sector operation of Mercury Technology plant was stopped in Dec 2012.Thereafter, this plant was taken over by Aditya Birla Chemicals ( India ) Limited in September 2013 & replaced old Mercury Cell process of 59400 TPA of Caustic Soda plant by latest state of Art Membrane Cell technology from M/s Uhde Germany .The other By-products are Hydrochloric Acid which is consumed for the manufacturing of Phosphoric Acid ,Liquid Chlorine & Sodium Hypo Chlorite. Caustic Soda manufacturing is power based Industry and unit requires 22MW power (Approximately 65% manufacturing cost is power cost) The business environment is multifaceted involving different technologies, various qualities of products for fragmented markets.

The Unit is also responsible for procurement of various raw materials and marketing and sales of its products. Initially, after meeting the requirements of Phosphoric Acid Plant, the excess material sold in the market at premium prices because there was a protected market and less supply of material in the market. With the changing time, the demand and supply position has completely been changed. There are as many as 38 players and total market suffers from excess supply of caustic soda.

The Indian Chlor-Alkali industry is facing a competition from global market and dumping of Caustic by other nations. By virtue of its strong commitment towards quality management, company has made efforts to setup Energy Efficient latest Membrane Cell Technology , New Chinese Brine purification Ceramic Filtration ,Variable Frequency Drive for critical Equipment to make the unit more Energy Efficient , Energy Conservation, Quality, Safety, Health & Environment.

The job holder is responsible for planning, monitoring, implementing and control Production& Maintenance activities of Caustic Soda Plant and VAPs so as to optimize plant effectiveness and power consumption to ensure that targeted production achieved with the budgeted cost and adherence to safety and environment including downstream products Liquid Chlorine, Hydro Chloric Acid, Phosphoric Acid and Sodium Hypo in alignment with business mission and EVA targets.

Major Challenge

• Attending the incoming main water line leakages since source is 35 Kms away from the Factory site.
• To maintain and upkeep the old deteriorated water distribution system for both Plant and Colony.
• Upkeep and maintain the other sources of water during water crisis.
• Timely upkeep and maintenance of all the existing Air conditioners and water coolers inside the plant and colony premises with limited resources.
• Attending the emergency rescue operations of the offsite road, tanker incidents.
• Remote location of the Unit demands for the emergency machining/ modification required to be

done at site.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 1. Plant Maintenance

Implement all maintenance activities in the plant 1. Follow schedules and timely implement daily maintenance activities in the concerned areas

• Check and report preventive maintenance, shutdown and predictive maintenance systems for abnormalities and take corrective action for elimination
• Implement the PM activities as per the schedule under coordination with concerned process plant and feed the data in the system
• Refer Chronic problems to superiors and concerned for advice and remedial measures
• Communicate and get organized necessary resources like material & manpower for uninterrupted & timely completion of maintenance jobs
• Take care of spare part management

KRA2 2. Cost Control & improvements

Act on cost reduction and process improvement plans within budgeted time and cost 1. Implement measures in design modification for cost reduction

• Suggest to the Section Head any measures for cost improvement/control
• Assist data collection, information to identify opportunities and Bottlenecks

KRA3 3. Reports and Documentation: Timely update all documents of the section 1. Timely preparation all relevant reports, MIS and update all systems

• Ensure update of documents as per ISO and related
• Assist in getting timely audits done in the section

KRA4 4. System Management (Safety, Sustainability & WCM): Adhere to statutory compliance related to Safety, Health and Environment & Sustainability and systems like IMS, WCM and ISO 1. Adhere to quality systems in the section for improving performance as per quality and environmental standards

• Implement IMS 9001, 14001, 50001, SA 8000, OHSAS 18001 & WCM practices & other systems in the Section
• Implement periodic sustainability audits action plans as directed by Sustainability Cell and other audits
• Handle emergency situations like Liquid Chlorine leakages, Road Tanker etc. under Onsite/Road Disaster Management activities
• Timely update documents related to ISO 9001 & ISO14001 for the department
• Participate in Kaizen, Suggestion Scheme, etc. and ensure implementation of audit findings

KRA5 People Development

Maintain a congenial work culture by effective communication with workmen both permanent & contractual 1. Maintain proper communication with workers and contract labour, their shift activities and resource requirements

• As and when required effectively communicate the management objectives and action plans for implementation