Designation
Location: India Telangana Basantnagar Cement Works
Organization: Cement
- *Job Description:**
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- *Position Title\-Department Head (Mechanical II\-Cement Mill \& Packing Plant) \- Assistant General Manager/General Manager**
- *Location: Sarlanagar Cement Works, Sedam**
- *Qualification: B.E. / B. Tech. in Mechanical Engineering**
- *Job Purpose**: To ensure **mechanical reliability, availability, and cost\-effective performance** of all equipment in **Cement Grinding (VRM/Ball Mill/Roller Press)**, **Cement Transport**, **Bulk Loading**, and **Packing Plant** (rotopackers, truck/rail loading, and bag handling systems). To lead strategy, people, and systems to achieve **production targets, quality requirements, dispatch commitments**, and **safety \& compliance**, while driving **continuous improvement, digitalization**, and **lifecycle asset management**.
- *Key Result Areas** **Supporting Actions****Accountability**\- Plant availability:
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Plan, organize and monitor implementation activities for optimum plant availability
- Provide strategic oversight to ensure uninterrupted and optimized operations of Cement Mills, Packing Plant, including rotary packers, truck/wagon loading, and loose cement systems.
- Direct daily packing and dispatch planning aligned with business and logistics targets.
- Review and improve operational KPIs such as packing rate, accuracy, downtime, and dispatch performance.
- Strengthen coordination with Quality to uphold packing and product standards.
- Optimize workforce deployment, shift productivity, and workflow strategies.
- Ensure adherence to dispatch plans and seamless integration with logistics operations.
- *Maintenance Management**
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- Lead the development and execution of preventive and predictive maintenance strategies for all packing plant and jetty equipment (packers, loaders, conveyors, bucket elevators, bag filters, compressors, weighing systems, etc.).
- Drive reduction in equipment failures, improve MTBF, and minimize MTTR.
- Establish robust spare parts planning with timely procurement and inventory control.
- Ensure accurate documentation of maintenance logs, SAP compliance, and equipment history.
- Provide technical leadership for resolving complex mechanical, electrical, and instrumentation issues.
- *Plant Equipment Up gradation \& Improvement**
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- Identify systemic bottlenecks and deploy process improvement initiatives to enhance throughput, reliability, and quality.
- Drive improvements in packing productivity, bag weight consistency, and overall equipment effectiveness (OEE).
- Implement loss?reduction measures for spillage, leakages, and material wastage.
- Champion Lean practices (5S, Kaizen, RCA, TPM) and institutionalize continuous improvement culture.
- Lead initiatives to optimize power consumption and operational cost efficiency.
- *SHE (Safety, Health \& Environment)** along with Sustainability initiatives
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- Ensure full compliance with statutory, corporate EHS guidelines and drive a proactive safety culture.
- Conduct and review toolbox talks, safety audits, risk assessments, and ensure closure of findings.
- Monitor and ensure effective performance of dust?control systems for emission compliance.
- Enforce strict PPE usage and safety protocols for employees and contractors.
- Oversee statutory inspections and maintain all regulatory documentation.
- *People Management \& Development:**
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- Lead, mentor, and develop a multi?disciplinary team of engineers, technicians, operators, and shift leadership.
- Drive technical capability building and continuous skill enhancement across operations and maintenance teams.
- Engage effectively with production, logistics, quality, stores, and contractor partners to ensure end?to?end operational alignment.
- Manage and govern contract workforce performance and compliance.
- *Dispatch \& Customer Interface**
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- Ensure precise, timely, and efficient truck/wagon/bulker loading as per dispatch and customer requirements.
- Strengthen coordination with transporters and dispatch teams to avoid delays and ensure smooth turnaround.
- Resolve issues related to bag quality, weight discrepancies, or loading inconsistencies.
- Ensure FIFO principles are consistently followed for product dispatch.
- *Cost Control:**
- *Plan, Monitor \& Control material**
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- Prepare and control annual O\&M budgets for the packing plant, including spares, manpower, and consumables.
- Drive cost?optimization initiatives across energy use, spares consumption, and maintenance activities.
- Evaluate and manage vendor/service provider performance to ensure cost?effective and quality services.
- Use digital tools (EOW dashboards, sequencing systems, TAT analytics) for optimizing packer allocation and dispatch workflow.
- Coordinate with logistics and railway officials for despatch control and cost optimization.