Head PBU Process

Job Purpose

• Job Purpose: Write the purpose for which the job exists (in 2-3 lines)
• To Ensure flawless operating discipline, daily work management, and continuous improvement as a culture across PBU.
• Develop the capabilities of the following line, lead significant initiatives, create value at the business level, and prioritize EHS and sustainability in line with the P&B and long-term roadmap.
• 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
  
  

Please review the below documents as they outline the job context and challenges for the Head- PBU Process. This role is crucial in addressing the complexities of manufacturing IGTs and ensuring that we have the skilled workforce and precision in production necessary to meet the market's requirements.

As the market's requirements are very dynamic (basically due to energy efficiency and sustainability), manufacturing IGTs has its own complexities. The most widely used IGT sizes for IGTs are 7 mm and 5 mm ODs, and wall thicknesses start from 0.19 mm. Sometimes, we must manufacture/develop our own variety of IGTs (basically R&D) and suggest to customers to be ahead of the competition.

As IGTs are highly customized products, we must be ready to cater to any immediate customer requirement to maintain business opportunities. This requires us to maintain the highest level of precision in our manufacturing processes, a task that is crucial to maintaining the quality of our products.

As this is a B2B product, considering the downstream application at the customer's works, we must maintain precise heat treatment. This is the most critical factor for final grain size, and it requires meticulous attention to detail and a deep understanding of the materials and processes involved.

With the demand for lower OD and wall thickness set to continue, the need for a highly skilled workforce becomes even more urgent. Your role in managing our operations is crucial to our success.

Whenever we want to cater to a new customer, we must undergo a rigorous approval process. This process, which can take a few weeks to more than three months, is crucial as it ensures that our products meet the highest standards and are tailored to the specific needs of each customer.

Currently, India is entirely dependent on the import of IG tubes. Well-established manufacturers, such as Jintian, Hailiang, MetTube, LS Metals, etc, supply these tubes. We must manufacture excellent-quality tubes to replace existing suppliers and establish a sustainable business.

• 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

• Identify health hazards that arise out of occupational, design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
• Embed a culture of safety to prioritize accident prevention at all levels of organization by following measures:
• Implement safety standards & procedures
• Develop safety mechanism / engineering controls (flange guarding, conveyor guarding, etc.)
• Facilitate safety related training to achieve zero harm
• Work in close co-ordination with all stakeholders to spread awareness.
• Ensure emergency handling readiness & training for crisis mitigation of all Cross Functional Teams across the PBU through continuous recording of special events, trip analysis, failure analysis, efficiency improvement, benchmarking, efficiency evaluation, etc.
• Adopt digital practices that enable safe work environment (online alerts for PPE violation, using AI for creating / refining / updating SOP for critical activities, remote monitoring of confined spaces, etc.)
• Ensure implementation of safety guidelines related to vehicular movement & material handling to control the associated risks in the PBU.
• Ensure that a proper system for following has been established:
• Abnormality Identification in DMTs
• Plan for elimination of unfavorable deviations / abnormalities
• Identification of countermeasures to address abnormalities.
  
  

(Countermeasures include Kaizen, SPL, Visual Controls, Mistake proofing, Change in SWI, etc. as an outcome of Root Cause Analysis and measurement of deployment effectiveness.)

• Supervise outsourced activities and cost reduction against all types of waste in the PBU.
• Review & ensure closure of actions identified against near misses, potential hazards, and various audits for closing the non-conformities.
• Ensure that all changes are made through MOC system, HAZOP / PSSR / HIRA is conducted for them, and all identified hazards & unsafe behaviors are addressed using relevant metrics by collaborating with CoE Process Care / PBUs.
• Ensure complete implementation of LOTOTO (Look-Out, Tag-Out & Try-Out) guidelines for personnel safety.
• Contribute as a memeber of the respective safety task force across PBU in implementing safety programs (confined space, contractor safety, etc.)
  
  

Operational Excellence & Cost Optimization

• Review and analyze effectiveness of SOPs & SMPs and recommend whether or not they are suitable for the PBU.
• Prepare project charter & a detailed project management plan for every major initiative or value creation project and execute them accordingly.
• Drive the culture of problem solving and value creation to address performance gaps (SQCDPM) and customer issues (internal & external) through FI, PI and Value creation projects.
• Prepare production plan and fix raw material consumption norms, to ensure budgeted production and efficiency.
• Review & monitor for effectiveness of FI, PI, Value Creation and other improvement projects in meeting their targets and future scope of improvement.
• Set & communicate clearly defined KPIV & KPOV (Key Performance Input / Output Variables) to AETs & DMTs with all the related costs, also ensure progress and that the deadlines are met for improvement initiatives.
• Plan & control the direct and indirect costs associated with PBU operations, monitor expenses against budget in order to achieve budgeted efficiency, better cost control and improve overall profitability.
• Prepare & execute PBU budget (CAPEX & Operating) and achieve monthly, quarterly and annual P&B targets of PBU and AETs, in line with annual business plan.
• Drive the following cost saving initiatives for, reduction of production cost and de-bottlenecking:
• Implement 3R's- Repair, Reuse & Recycle
• Collaborate with unit and corporate procurement teams to develop alternate raw materials, vendors, etc.
• Ensure actions to, control inventory of raw materials, WIP, & finished anodes and achieve working capital for the day through regular Inventory review & Scrap management, in line with annual working capital plan.
• Ensure material, manpower & contractor job planning and resource deployment & arrangement as per need, to maximize profitability.
• Identify gaps in various utilities & their consumption (Steam, Power, LSHS & fuel), propose countermeasures and partner with AETs for their deployment.
  
  

Asset Care & Equipment Reliability

• Identify major initiatives & value creating CAPEX projects for the PBU to enhance productivity, mitigate obsolescence, and improve efficiency.
• Ensure asset care practices are implemented for availability and reliability as per excellence standards in PBU to achieve the target of zero equipment breakdown by improving OEE and Process capability under the challenges of ageing, OEM obsolescence / limited support, custom equipment and complexity due to diversity of equipment in the system.
• Ensure implementation of best maintenance practices across the PBU and monitor its effectiveness in coordination with CoE-Asset care, to attain higher uptime of Plant and equipment.
• Plan & ensure that AET members are trained in effective use of 'Maintenance Strategic Frameworks' (RCA, FMEA, LLF, CLIT, PM analysis, RCM, CAPA, MTTR, MTBF, OEE, etc.)
• Undertake following measures for a successful shutdown & overhaul job:
• Partner with CoE Asset Care, in planning & execution
• Ensure availability of spares, skilled manpower, special tools & tackles, etc.
• Implement PERT / CPM network for different phases of the job.
• Manage working capital by optimizing spare consumption at different inventory levels in PBU for raw materials, spares, and any other consumables for the purpose of improving profitability.
• Develop plans for technology upgradation, automation and digitalization for long term sustainability of operations and maintenance in the PBU.
  
  

Process Excellence & Quality

• Plan & ensure that AET members are trained in effective use of 'Process Care Frameworks' (FMEA, SPC tools & techniques, Six Sigma, TRIZ etc.)
• Ensure implementation of finest process care practices across the PBU and monitor its effectiveness in coordination with CoE-Process care, to achieve higher efficiency and quality.
• Ensure implementation of IMS (ISO-45001, ISO-9001, and ISO-14001), IATF16949, AS9100, CE, ASI, etc. in line with audit requirements to ensure 100% compliance.
• Drive flawless daily work management system by implementing PBUT, AET, DMT & COEs excellence standards across PBU and ensure adherence to quality parameters.
• Ensure formulation & implementation of SOPs and SMPs across PBU.
• Achieve the targeted production as per quality specifications benchmarked with international standards and changing customer needs.
• Ensure adherence to laid down processes & practices pertaining to manufacturing without any deviations, to attain consistent product quality.
• Ensure execution of 'New Product & Process Development' initiatives as per changing business & customer needs.
• Lead the way to build 'Technology Upgradation Roadmap' and address current and future technological needs of the business.
• Develop system and processes to identify major initiatives & large value projects related to process leadership for PBU.
  
  

Customer Centricity

• Ensure OTIF (On-Time-In-Full delivery) as per the commitment to internal & external customers.
• Meet and exceed internal & external customer expectations, adhere with service level agreements (SLAs), and ensure implementation of action plans based on ICSI, customer feedback & surveys.
• Ensure timely dispatch of material from the Plant and coordinate with Zonal Marketing Team on regular basis to ensure fulfilment of customer requirements.
• Ensure company-wide implementation of initiatives such as Mission Happiness, Net Promoter Score, ICSI, etc. to monitor customer satisfaction and undertake preventive & corrective measures to maximize satisfaction.
• Interact with domestic and export sales team for primary metal and downstream products, to ensure alignment of sales and production plan to realize maximum sales and resolve customer complaints, if any.
• Participate in organizational initiatives for Customer Relationship Management, conduct periodic customer-supplier meets (both internal & external), and capture & report feedback for ‘Voice of the Customer.’
• Interact with warehouse and logistics team to ensure adequate supply of quantity & quality of primary metal so that timely dispatch takes place.
• Support in the formulation of SLAs of AETs & DMTs with other stakeholders and suggest any improvements.
  
  

Capability Building & People Engagement

• Promote a culture of recognition, appreciation, and celebration to motivate & engage personnel not only for better results but for demonstrating right behaviors (ALERT & CASIO).
• Encourages & promote improvement activities / initiatives - 5S, Kaizen, FI, PI and customer centricity through regular reward & recognition.
• Create forums & platforms for the following:
• Two way communication with employees (including contract workmen, supplier and any other key stakeholder.)
• Active interaction of AETs & DMTs across PBUs within the Vertical.
• Create learning architecture (curriculum, courses, and learning modules) using blended learning approach - a combination of education, exposure and experience.
• Promote a culture of delegation & empowerment by giving employees autonomy to make decisions in their area of work by leveraging MPH Platform.
• Develop an internal trainer pool and facilitate training sessions for AET & DMT members to build their technical and behavioral capability.
• Ensure that a proper system for succession mapping & development is in place for all levels of organization with special focus on identifying and building succession pipeline for Business Critical Roles / Positions.
• Identify and address capability gaps according to requirement of a role and train / handhold AETs to do the same.
• Ensure that system is in place for skill / competency mapping for both technical & behavioral needs and skill inventory of AETs & DMTs have been maintained.
  
  

Risk Management & Sustainability

• Develop, upgrade & adapt technology for sustainable practices (disaster management for Level 1 & 2 equipment’s, CERT guidelines, etc.).
• Ensure compliance through regular reviews of all statutory, regulatory & environmental norms and HIL standards for Occupational Health, safety & environment to the satisfaction of all statutory bodies / auditors with focus on:
• Environmental guidelines of CPCB (Central Pollution Control Board)
• Hazardous waste management
• Emission monitoring to control air & water pollution.
• Identify value creation projects which have long term impact on the unit and business, facilitate ideas from team members around 'Value destruction' & 'Missed Value Creation' and ensure that they are implemented, for long term sustainability.
• Institutionalize Enterprise Risk Management and Business Continuity Plan for PBU, undertake sustainability risk assessment / heat map, determine the level of risk by ensuring 100 % monitoring, review, & action on risk register, and plan mitigation strategy.
• Drive strategic / large scale improvement initiatives under the guidance of Vertical Head and ensure all statutory requirements in PBU are met with focus on air and water pollution control, for hazardous wastes and effluents.
• Optimize power consumption and embed sustainable practices towards energy saving including partnering in green initiatives across the Vertical.
• Develop sustainability roadmap in line with Plant / Group aspirations and conduct regular reviews to monitor its implementation.