AET Mbr Ops

Job Purpose: Write the purpose for which the job exists (in 2-3 lines)
Lead, Plan, organize, execute, and drive operations in Refinery 3, focusing on continuous improvements in production, cost, quality, while ensuring high-quality product delivery that exceeds customer expectations and complies with safety, regulatory, and environmental standards as per P&B/ Business target through flawless daily work management and a culture of excellence in AET and ensure effectiveness of cross functional collaboration in DMT.
Ensure that the process control system are in place and align it with the overall goals of the organization. Providing the roadmap for the future development and ensuring compliances with industrial standards and regulations
To deliver high quality products that meets/exceeds external customer expectations within industry standards with cost efficiency and timely delivery.
Dimensions:
Business/SBU/Unit Revenue
Revenue : 52,000 Crs (FY-24)
EBIDTA : 2400 Crs (FY-24)
Business Workforce Number
MG:630
Staff: 410
Worker: 900
Contract: 5000
Unit Workforce Number
MG: 420
Staff: 325
OG: 900
Workmen: 4000
Function Workforce Number
Staff: 132 (Management), 95 (LMS)
Company Workmen: 433
Contract Workmen: 659
Total Strength: 1319 Nos
Department Workforce Number
Staff: 10 (Management), 13 (LMS)
Company Workmen: 60
Contract Workmen: 120
Total Strength: 203 Nos
Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter
Budget as per P&B – Rs. 149 Crs
Number of units: 1
Volume: Cathode: 198000 MT
Internal Customer: 150000 MT
Sale: 48000 MT
Nos. of By Products -
De-copperised Slime – 1000 MT
Liberator Cake – 600 MT
Expenditure –Capital Budgets: 60 Cr,
Research/Technology Development -
Cell Prototype research & technology Development
Critical Equipment -
High Speed EOT Cranes (2 Nos.)
Rectifiers (4 Nos)
Cathode stripping Machine (2 Nos)
Anode Preparation Machine (1 Nos)
Spent Anode washing Machine (1 Nos)
Electrolyte Circulation Pumps (4 Nos)
No of Confined Space – 16 Nos
No of Total Work permit – 240 / month
No of Special work Permit – 180 / month
No of Haz Waste Management -
Cu – As Sludge (30 MT)
Liberator Cake (600 MT)
Power Consumption: 79 million KWh
No of SOP/SWI: 95 / 120
No of Trailers managed: 3 nos. per day (@24 Hrs basis)
Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business/Unit/Function/Department/Section
Job Context
Birla Copper has a copper smelting and refining complex at Dahej producing copper cathodes, cast copper rods, precious metals such as gold silver and selenium, fertilizers, and other biproducts such as sulphuric acid, phosphoric acid etc. in multiple plants with different technologies requiring diverse competencies. There are approximately 1500 employees, across functions at the Dahej unit of which about 350 are in the management cadre. This role is responsible for the operations of Refinery 3. Anodes of 99.5% purity supplied by Smelter 3 is processed to produce cathode of LME grade A of 99.99% purity for sale in the market or supply to CCR plant for further processing as copper rod. Cathode, being registered under London Metal exchange requiring stringent quality control. The key aspect of this role is to ensure production of cathodes as per budgeted quantities with required quality specifications. Implementation of norms of relevant, quality standards and health, safety environment norms. It involves driving continuous improvement of efficiencies through process improvement and upgradation of skills.
This role is responsible Sustainable Operation of Refinery 3 by finding creative solutions to long standing issues and recognizing AET / DMT team members for good work. The most critical element of the role is achieving desired product quality while meeting production target fulfilling LME compliances.
Ensuring the efficient and effective planning of the Refinery by monitoring and controlling processes, analyzing production data, MIS of inward, outward and WIP and implementing process improvements. Optimize plant performance, product quality, and safety while minimizing costs and environmental impact.
Tracking of inventory of Refinery at various production stages and ensuring that it is within targets, reconciling with monthly financial records.
Major Challenges
Refinery is highly complex, automated plant with synchronized operations of interlinked machines with a centralized communication management system. To ensure smooth operation & maintenance, it requires advanced knowledge in all the operational areas of Process
The products are directly used in end applications and hence critical to customer and their applications. Knowledge of Refinery Operations, Efficiencies and requirements of Quality Parameters is very important to understand and execute refinery operation as required to produce LME Grade Product.
Compliance to stringent quality standards.
Meeting stringent Product Quality of FG with varying sources of Raw material (concentrate).
Adhere to Legal and environment compliance with respect to emission & zero discharge of air, oil, and water i.e., conservation natural resources, energy etc.
The entire plant network, communication system, PLC, logic-based hydraulic system, requires high level of analytical skills during troubleshooting of the problem.
To sustain lowest cost producer of Refinery.
Process Optimization :
Quality of anode varies on account of variation in quality of concentrate affecting quality of final cathodes sold as finished goods and acceptance of production in domestic and export market. Rigid control is maintained on process parameters, reagent addition and other operating practices to avoid impurity build-up in solution, nodulation in cathode surface.
Equipment Reliability :
Preventive Maintenance : Equipment’s including Slime area pumps, Filters, Autoclave, RFT, Commercial Rectifiers area equipment’s meets PM compliances, statutory compliances.
Unplanned Downtime : Managing and mitigating the impact of unexpected equipment failures or breakdowns during shift hours, which can lead to costly downtime and reduced productivity.
Safety Management :
Risk Mitigation : Identifying and managing risks associated with Bismuth area, CRP plant, Cell house, circulation system and other hazards inherent in the Refinery process.
Compliance and Training : Ensuring all personnel are properly trained and compliant with safety regulations, and maintaining a culture of safety awareness.
Cathode Quality Control :
Cathode quality Consistency : Maintaining the consistency and quality of the Electrolyte and Cathode quality which is crucial for optimal Refinery and CCR performance. Variability in concentrate quality can affect process stability and efficiency.
Performance Variability : Addressing and correcting issues related to Cathode slime and electrolyte performance that could impact the overall efficiency of the Refinery process.
Data Analysis and Process Monitoring :
Interpreting Data : Analyzing process data to make informed decisions and adjustments. This involves understanding complex data sets and trends to proactively address potential issues.
Real-Time Monitoring : Ensuring real-time monitoring systems are functioning correctly and providing accurate information for immediate decision-making.
Balancing these challenges effectively is crucial for achieving operational excellence, ensuring safety, and maintaining the overall efficiency and reliability of the Refinery process.
Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)
Key Result Areas
Supporting Actions
Safety & Workplace Management
Ensure that all changes are made through MOC system, HAZOP / PSSR / HIRA is conducted for operation team, and all identified hazards & unsafe behaviors.
Drive strategic improvement initiatives under the guidance of AET leader and ensure all safety standards implementation like PTW & LOTOT, work at height, chemical safety, and confined space.
Implement procedures & plans, for compliance through effective BBSO, PI and identification unsafe act and unsafe condition.
Identify health hazards that arise out of occupational, design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
Drive Kaizen and other improvement initiatives for greater sustainability of operations.
Maintain workplace in order with respect to all Sub-areas (Level of 5-S).
Ensure the implementation of Gas cylinder, HIRA standards as per SAQ in Refinery-3
Daily Work Management
Drive flawless

Work arrangement
No