Mechanical Shift Incharge - Kiln and Coal Mill

Key Responsibilities

Maintenance Management

• Plan and execute preventive and predictive maintenance of Coal Mill-2 and associated systems.
• Ensure quick resolution of breakdowns with minimum downtime.
• Monitor condition of critical equipment like mill internals, gearbox, bearings, classifier, feeders, and bag filters.
• Maintain optimum equipment availability and reliability.
• Know about the SAP, item codification, equipment codification. Need to close the Work orders , give feedback & able to generate orders.
• Know about the RCA tools & able to perform the RCA of breakdowns with cross functional team.

Operational Support

• Coordinate with the Production team for smooth mill operation.
• Ensure proper coal grinding parameters are maintained (fineness, moisture, temperature).
• Support kiln operation by ensuring consistent pulverized coal supply.

Inspection & Condition Monitoring

• Conduct regular inspections of:
• Grinding rollers & table, ball mills liners
• Mill gearbox & lubrication system
• Hydraulic system
• ID fan & ducts
• Implement vibration analysis, oil analysis, and thermography.

Shutdown Planning & Execution

• Prepare detailed shutdown plans for Coal Mill-2.
• Ensure availability of spares, tools, and manpower.
• Execute shutdown jobs within planned timelines and quality standards.
• Requires availability during shutdowns and emergencies

Safety & Compliance

• Ensure strict adherence to safety standards and SOPs, especially for:
• Fire and explosion hazards in coal grinding
• Hot work and confined space jobs
• Conduct safety audits and toolbox talks.
• Ensure compliance with statutory and environmental norms.

Spare & Inventory Management

• Identify and maintain critical spares inventory.
• Raise PRs and follow up for procurement.
• Optimize inventory to reduce cost without affecting reliability.

Team Management

• Lead and supervise a team of engineers, supervisors, and technicians.
• Allocate jobs and monitor execution.
• Train team members to enhance technical competency and safety awareness.

Continuous Improvement

• Identify and implement reliability improvement initiatives.
• Work on energy optimization and cost reduction projects.
• Analyze recurring failures and implement root cause corrective actions (RCA).

Key Performance Indicators (KPIs)

• Equipment availability (%)
• Breakdown frequency & MTBF
• Shutdown adherence (time & cost)
• Maintenance cost control
• Safety compliance (Zero accidents)
• Coal mill output & efficiency

Key Skills

• Strong knowledge of coal mill systems (VRM/Ball Mill)
• Maintenance planning & troubleshooting skills
• Knowledge of hydraulics, lubrication, and gear systems
• Leadership and team handling ability
• Safety awareness and compliance

Exposure to dusty, high-temperature industrial environment