Asahi India Glass - Section Head - Furnace Operation & Maintenance

Role Name: Sec-Head (Furnace Operation & Maintenance )

Role Description : Responsible for delivering glass quality as per specification and requirement

Role purpose:

- To manage smooth & efficient functioning of Furnace operations and maintenance

Document created by : Goutam Dhar

Responsibilities Heads: Safety

KRA (Key Result Areas) :

Of Manpower:- To assist dept head in preparation & execution of SOP's for safety so as to develop safe working environment.

Of Assets : - To Coordinate with other depts to execute & ensure maintenance & up gradation of existing asset.

- Ensure emergency preparedness at any given time to meet exigencies like Glass leakage, Dog House Silo empty, Fire, Furnace Firing Failure

KPI (Key Performance Indicators):

Safety performance index

- Continuous Training on Safety Norms.

- Safety audit score

- Audit report carried out by external / recommended agency.

- Maintenance plan vs. actual

- Gaps identified during mock drill operation and action plan

Responsibilities Heads: Budgeting

KRA (Key Result Areas) : To make annual budget for Consumables, Safety items and Refractories for Furnace maintenance and consumption of utilities

KPI (Key Performance Indicators): Timeliness of budgets submission

Responsibilities Heads: Budget control

KRA (Key Result Areas) : Monitoring of consumption of utilities.manpower, spares consumables and refractories

KPI (Key Performance Indicators): Action plan for the gaps identified during variance analysis

Responsibilities Heads: Production

KRA (Key Result Areas) :

- Regular coordination with M.Bath & RMH section to make plan for Pull Change and Furnace parameters adjustment

- Ensure the quality standards of Furnace Oil and HSD on continuous basis, consumables and spare refractories

- To undertake improvement initiatives for production equipments, processes and systems as per business requirement.

- To ensure smooth operations of Furnace control parameters to produce glass quality as per specifications.

- Maintain of optimum inventory of Critical Refractory items,Consumables and Safety items

- To stabilize the process parameters of the furnace during colour change in order to achieve the stabilize the new tint

KPI (Key Performance Indicators):

- Budget vs Actual

- Adherence with Quality Standards as per AIGL

- No. of PDCA. Plan vs actual saving

- Primary Defects Rejection %age in each production run.

- Adherence to the norms

- Target vs Actual

Responsibilities Heads: Maintenance Support

KRA (Key Result Areas) :

- To monitor and review Furnace maintenance plan in coordination with maintenance dept

- Ensure checking of overall Furnace Refractory corrosions / conditions and sealing conditions

KPI (Key Performance Indicators):

- Timeliness

- As per checksheet

Responsibilities Heads: Quality Management ( Standardization of Systems )

KRA (Key Result Areas) :

- To Implement TQM,QMS as per company guidelines.

- To standarize the process by making suitable SOP and implementation of the same

KPI (Key Performance Indicators) :

- TQM Audit score / No. of NCR's in internal / external audits.

- No of abnormalities identified and action taken during process audit

Responsibilities Heads: Cost reduction

KRA (Key Result Areas) :

- To execute the plan in order to reduce the utility consumption in the process.

- To strengthen the Task group activity in order to reduce cost.

- Enhancement of Furnace life

KPI (Key Performance Indicators) :

- Consumption of NG, Furnace Oil, HSD, Propane

- Cost savings plan vs. actual

- Action recommended in Audit report carried out by external / recommended agency.

Responsibilities Heads: Development - Manpower

KRA (Key Result Areas) :

- To evaluate the skill matrix in department members as per roles and responsibility

- To execute appraisal as per company guidelines

- Preparation of Training Manuals related to process for effective training of the operatives

KPI (Key Performance Indicators) :

- Updation of Skill matrix Training plan vs. actual

- Timeliness of Appraisal Annual review plan vs actual.

- Timeliness

Responsibilities Heads: Product Development

KRA (Key Result Areas) :To carry out deep analysis and develop product samples as per market requirement

KPI (Key Performance Indicators) : Timeliness

REQUIREMENTS:

- Knowledge Fair knowledge of Glass Manufacturing process, Different types of Raw Materials and Colorants, Emergency Handling, QMS,Suppliers

- Experience '(Number of years) 8~ 10 yrs.

- Skills : Managerial, Communication, 360'Leadership and motivation.

- Qualification B.Tech ( Ceramics )

INTERACTION: Internal: Production dept, QA,Maintenance dept,Store

Customers : Quality Dept, Production

Other External parties/Vendors : Technical adviser (Glaverbel, AGC), RM supplier