Shri Mahavir Ferro Alloys Private Limited (SMFA) started its operations in 2003-04 with a 100 TPD sponge iron kiln at the Kalunga Industrial Estate in Odisha. The company further expanded the capacities of its sponge iron plant with the addition of a third 100 TPD Kiln along with two 12 Ton induction furnaces with a Continuous Casting Machine (for Billet casting) in the year 2008. Adding one more feather to its expansion program, SMFA commissioned a 12 MW coal-based Captive Power Plant in March 2008 to meet the power requirements of its three 100 TPD sponge iron plants and steel melting shop (SMS).

SMFA has its railway siding, which was approved by the South eastern Railways in the year 2007, and its design and engineering got approved in 2009. The company upgraded the railway siding to a private freight terminal to cater to plants’ requirements and get the benefit from railway policies along with the added business opportunities with the various manufacturing plants in the vicinity. In 2011-12, SMFA ventured into producing power using renewable sources by commissioning a 1 MW solar power plant under the Jawaharlal Nehru National Solar Mission at Tankajoda village in Sundargarh district of Odisha.

Strategic and tactical responsibility for implementing manufacturing plans and operational goals to exceed customer expectations for product quality, cost and delivery, maximising the efficiency, optimising production levels and driving operational excellence, for all the functions of the SMS plant, including the furnace, continuous casting machine and slag recovery.

- Create and implement best practice manufacturing processes and procedures to aid and improve business performance
- Drive improvement projects to enhance throughput / yield / improve product quality / reduce cost & wastage
- Implement a customer focused operational culture delivering world class customer service levels

- Ensure daily production of billets as per business plan and communicate the same to top management
- Ensure billet yield is above the target set as per the business plan
- Ensure specific consumption of raw materials (sponge iron, MS scrap etc) is below the target
- Ensure the specified feed mix – sponge iron: billet
- Ensure continuous feed of sponge iron from stock houses to SMS – quantity & quality; scrap / recovered slag for uninterrupted billet production.

- Ensure maximum SMS uptime in coordination with process head & maintenance head
- Plan and optimise shutdown maintenance duration and cost

- Drive root cause analysis (RCA) process for any process / quality deviations
- Ensure compliance to corrective and preventive actions (CAPA) action plan

- Ensure produced billets meets the specifications of the external customer – in terms of C/Mn/S/P/Si and grade consistently
- Ensure reduction in runner riser / fresh short length production over prev. baseline

- Make the annual budget for overall SMS plant
- Ensure actual cost v/s budget is under control
- Ensure accounting of fixed & variable cost of SMS plant to understand the per ton cost of production of billet (manpower, raw materials, spares, consumables, power etc.)

- Provide leadership to departments under control and coach, mentor and develop direct reports and manage a high performing team that delivers continuous improvement, added value and cost reductions
- Set department objectives and monitor ongoing progress and performance
- Ensure technical / business training hours for Pellet/Beneficiation/PGP/PCI team is complied
- Ensure no production outage due to manpower shortage

- Ensure zero safety incidents & lost time injury
- Ensure compliance to pollution norms in all plants
- Ensure compliance for IMS standards
- Promote & monitor 5S in all areas of the plant

- Daily / monthly production plan vs actual achieved

- Achieve daily yield more than the target

- Number of complaints received from the customers because of the poor quality of product (Internal or External)

- Drive teams to perform root cause analysis for breakdowns / process deviations
- Complete RCAs within 2 days
- Compliance to CAPA action points as per defined timelines

- Spares & Consumables (S&C) consumption per month less than the target
- Power per ton of billet (or process heat time or melting rate) less than target
- Wastage reduction
- Drive cost optimization projects

- Zero lost time injuries / accidents
- Compliance to EHS and other legal standards
- Train / coach team members on EHS
- Maintain and monitor 3S standards in your department /circle

- 100% adherence to IMS standards
- Implement best practices
- Zero NCs in external audits
- Train / coach team members on IMS / SOPs
- Complete all level 1/2/3 3S activities

- Work experience as a HOD or Process Head of SMS plant with induction furnace and CCM technology
- B.E – Metallurgical / Mechanical

- Min. 15 years of relevant experience required