Heading Process Optimisation department

Monitoring the process parameters; ensuring compliance with process parameters; solving process related problems in case of any deviations from optimum productivity levels # Enhancing production process operations, optimizing resources & maintaining quality & escalating operational efficiencies# Material planning, scheduling & inventory optimization based on monthly production & annual shutdown planning by using SAP PP,MM & PS Module # Optimization of fuel mix and fuel cost, Refractory cost # Optimizing usage of Fly ash, Gypsum and other raw materials.# Production & CCR manpower management including third party contract allocation for various production/Process job# Process Modification job for usage of Low grade fuel in Kiln & calculation for maximum LGF usage without productivity loss & saving of thermal energy cost per MT of Clinker# CAPEX Projects execution, plant operation (Kiln, Ball mill, VRM, Roller press), process monitoring and modifications and technical services for plant optimization and cost reduction# Process calculation & process modification for electrical & thermal energy saving# Energy audit for Entire Cement Plant with improvement suggestion & Implementations # Implementing cost reduction programs, by carrying out modifications, process / implementation of Best Practices. # Implementation of safety and ISO systems in the department # Improvements and ensuring cost reduction targets are met.# Training to Process/Production peoples for various activities like CCR Operation, Refractory selection & installation, AFR, Process Calculation…etc. . # Ensuring the skill and motivation of production personnel in complying with process discipline.# Ensuring optimum utilization of manpower resource.# Lead people resources to ensure maximum productivity of employees.# Identify and develop talent within the department & technical training needs of the team & prepare skill matrix for the team

 Perform routine production jobs with proper risk assessment and standard operating procedures. Perform all process parameter tracking and reasons for deviation from targets. Perform process calculations including Heat balance, fan flow calculation and efficiency. Perform ambient and stack air monitoring as per stringent environmental norms. Performed basic burner momentum flame calculation and burner pipe alignment as per standards. Daily tracking and optimization of production as well as power consumption of entire plant. Suggested maintenance dept. for any process modification

Kiln, Cement mill, Raw mill Operations.  Awareness of pyro process, raw mix grinding, finish grinding. Hands on Experience on:o Study of heat and energy conservation.o Process optimization ( Fan efficiency calculations Heat losses, False Air in Leakage across system).o Break down, down time and machine availability analysis.o Refractory planning and execution work During Shut down.o Inventory management of Process/Production Department (Grinding Media & Refractory)o Co-ordination to all internal & external audits for ISO-9001, ISO-14001,& OHSAS-18001..o Alternative fuel & Raw material handling o Co-ordinate all activities for implementation & successful operation of SMARTo Involved in Internal as well as External Safety Audits of the Department.o Monthly performance report of plant.o Cement Mill (Ball Mill) Optimization. Time management skills and the ability to prioritize tasks Ability to work effectively and make measurable contributions as a team player Strong administrative, organizational, and coordination skills