Mechanical Engineer

Job Purpose

To oversee and execute mechanical maintenance activities for all five production lines, ensuring smooth and uninterrupted plant operations.

Job Context & Major Challenges

Birla Carbon's Gummidipoondi unit, established in 1998, has grown to include five production lines with an annual capacity of approximately 237,250 MT of carbon black. The facility also boasts a 60.7 MW power generation capacity and a 15,000 MT per annum rubber master batch production capability. The unit adheres to stringent quality, environmental, and health & safety standards, including IATF 16949:2016, ISO 14001:2004, and OHSAS 18001:2007. This role is critical for maintaining all rotating and stationary mechanical equipment used in carbon black production and power generation, ensuring continuous operational availability and regulatory compliance. Key challenges include minimizing breakdowns and downtime to enhance Overall Equipment Effectiveness (OEE) and Overall Plant Effectiveness (OPE), improving environmental performance by preventing emissions and leakages, reducing repair and maintenance costs, effective manpower planning during shutdowns, and ensuring adherence to all regulatory requirements.

Key Result Areas

Mechanical Maintenance

Execute mechanical maintenance tasks to ensure trouble-free operations. Plan and schedule maintenance for breakdowns and shutdowns, ensuring timely completion with efficient manpower utilization. Coordinate with production and other departments during maintenance activities. Maintain site cleanliness post-maintenance and manage spare parts to minimize wastage.

Preventive Maintenance

Monitor and implement preventive maintenance schedules to reduce breakdowns and maintenance costs. Identify and resolve issues in rotating equipment. Track spare parts consumption and oversee in-house fabrication of critical spares and equipment.

System Management

Implement and maintain the maintenance management system to ensure high-quality maintenance practices. Ensure documentation meets IATF:16949:2016 and ISO:14001 compliance. Follow established procedures and work instructions for breakdowns and planned maintenance. Participate in internal and external audits and develop necessary procedures and work instructions.

Safety

Enforce global safety standards, procedures, and legal compliance to foster a safe working environment. Maintain OHS:18001 compliance documentation. Conduct statutory pressure vessel testing and provide on-the-job safety training. Monitor workmen during critical tasks to ensure safe practices.

Training and Development

Engage in team initiatives to enhance competency levels. Participate in Quality Circle, KSS, 5S, and WCM activities. Conduct training on preventive maintenance techniques and clarify work procedures on the shop floor.

Spare Parts Management

Ensure the availability of necessary spares for uninterrupted plant operations. Identify critical spares and maintain adequate stock levels. Plan and oversee the procurement of spares and materials for all production lines, including 4A and 4B. Collaborate with Purchase and Stores departments to optimize inventory levels.

Continual Improvement

Drive continuous upgrades of mechanical systems for enhanced efficiency and reliability. Evaluate technical and commercial aspects of proposed modifications and their expected benefits. Plan project works, identify critical activities, mobilize resources, and monitor progress to ensure timely completion. Initiate and manage improvement projects.

Capex

Oversee the execution of capital expenditure (Capex) projects and new project implementations, specifically focusing on mechanical aspects.