Oversee the maintenance, reliability, and calibration of field instrumentation, control systems, and monitoring devices across the plant. Lead preventive and corrective maintenance strategies to minimize downtime, maintain safety standards, and manage operational budgets while leading the instrumentation team.
Key Responsibilities & Operational Functions
Instrumentation & Plant Equipment Maintenance
- Oversee maintenance, troubleshooting, and reliability of field instrumentation across key cement plant assets, including stackers, reclaimers, crushers, vertical mills, IKN/FLS coolers, conveyors, bag filters, and process fans.
- Ensure smooth operation of all process control loops (pressure, flow, level, temperature, and vibration monitoring).
- Maintain in-depth, hands-on knowledge of PLC systems, PCS7 architecture, servers, switches, CPU modules, and communication networks.
- Manage weighing systems (belt scales, packer scales, load cells) to ensure ongoing accuracy and calibration integrity.
- Maintain process analyzers (gas analyzers, dust monitors) through preventive checks and timely calibration.
- Ensure proper maintenance of control panels, marshalling panels, PLC panels, and instrument cabinets.
QCX & Laboratory Automation Systems
- Maintain a basic operational understanding of QCX Automation, Gamma Matrix/CBX, Robo Lab, and ARL X-Ray systems, coordinating with specialists as necessary.
- Ensure backups, documentation, and system communication links between QCX and central plant control systems are regularly updated.
Calibration, Quality & Compliance
- Manage calibration schedules for all process instruments in alignment with ISO/IMS standards.
- Maintain comprehensive technical documentation, including drawings, manuals, cause-and-effect charts, instrument indexes, loop diagrams, and system backups.
- Enforce bypass governance by maintaining bypass registers and ensuring no modification occurs without prior approval from the Plant Director / Chief General Manager.
- Ensure full compliance with all relevant statutory maintenance requirements.
Maintenance Governance & Reliability
- Lead preventive, predictive, and corrective maintenance programs to eliminate downtime and maximize equipment availability.
- Perform Root Cause Analysis (RCA) on instrumentation failures and implement corrective actions.
- Track breakdowns, stoppages, and maintenance actions within SAP.
Inventory, SAP & Budget Management
- Prepare Purchase Requisitions (PRs), monitor stock levels, and manage timely procurement of critical instrumentation spares.
- Manage the instrumentation operational budget, covering consumables, Annual Maintenance Contracts (AMCs), calibration tools, and improvement projects.
- Oversee the end-to-end lifecycle of SAP work orders (creation, execution, and closure).
- Lead, mentor, and develop the instrumentation team to enhance technical competencies and promote safe work practices.
- Collaborate with cross-functional teams, including Mechanical, Electrical, Production, Quality, and Automation.
- Promote a Zero Accident culture by strictly enforcing safety policies and IMS standards.
Key Performance Indicators (KPIs)
- Downtime: Reduce year-over-year instrumentation-related downtime.
- SAP Execution: Achieve at least 80% completion of all raised SAP work orders.
- Planned Maintenance: Complete a minimum of 80% of scheduled planned maintenance activities.
- Safety: Maintain zero recordable accidents within the instrumentation team and contracted workforce.
Competency & Qualification Requirements
- Education: Higher National Diploma (HND), Bachelor of Engineering (BE), or Bachelor of Technology (B.Tech) in Electrical or Electronic Engineering.
- Experience:
- Minimum 15 years of total industrial plant experience.
- At least 10 years of recent experience in a modern cement plant.