Job Description – Engineer / Senior Engineer (Mill & VRM In-charge)
Role Scope: Engineer / Senior Engineer (Mill & VRM In-charge)
Department: Process & Production
Location: Meghalaya
Experience: 4–6 Years (Experience in Cement Plant – Vertical Roller Mill (VRM) & Cement Mill Operations Preferred)
Qualification: B.E./B.Tech in Chemical Engineering / Mechanical Engineering / Cement Technology/ Diploma in Chemical or Cement Technology/ B.Sc./M.Sc. Chemistry (Preferred with relevant cement plant experience)
Role Overview
The Engineer / Senior Engineer (Mill & VRM In-charge) is responsible for ensuring the safe, ficient, and uninterrupted operation of the Vertical Roller Mill (VRM), Cement Mill, and associated grinding systems. The role involves monitoring and optimizing grinding operations through CCR/DCS, achieving production and quality targets, reducing specific power consumption, coordinating maintenance activities, and ensuring compliance with safety, quality, and environmental standards. The incumbent shall drive continuous process improvements to maximize mill availability and operational efficiency.
Core Responsibilities
1. Mill & VRM Operations
Operate and monitor Vertical Roller Mill (VRM), Cement Mill, separators, bag filters, weigh feeders, conveyors, and auxiliary grinding equipment through CCR/DCS.
Ensure smooth start-up, shutdown, and stable operation of grinding systems.
Monitor critical operating parameters including:
o Mill Feed Rate
o Grinding Pressure
o Differential Pressure
o Separator Speed
o Mill Outlet Temperature
o Main Drive Load
o Roller Vibration
o Hydraulic Pressure
o Fan Performance
o Specific Power Consumption
Maintain optimum mill throughput while ensuring consistent cement quality.
Optimize grinding performance by controlling clinker, gypsum, fly ash, slag, limestone, and other additives.
Ensure uninterrupted production with minimum operational disturbances.
2. Process Optimization & Quality Control
Optimize grinding parameters to achieve target Blaine, residue, fineness, and cement strength.
Analyze process trends using DCS data and recommend corrective actions.
Monitor grinding efficiency and improve separator performance.
Coordinate closely with the Quality Control Department to maintain product quality.
Optimize additive ratios based on clinker quality and customer requirements.
Identify opportunities for process improvement and energy conservation.
Minimize specific power consumption while maximizing production.
3. Equipment Monitoring & Maintenance Coordination
Monitor the condition of:
o VRM Rollers & Grinding Table
o Separator
o Gearbox
o Hydraulic System
o Lubrication System
o Process Fans
o Bag Filters
Detect abnormalities such as:
o High vibration
o Mill choking
o Hydraulic failures
o Roller wear
o Separator malfunction
o High differential pressure
o Excessive power consumption
Coordinate with Mechanical, Electrical, and Instrumentation teams during preventive and breakdown maintenance.
Participate in shutdown planning, inspection, trial runs, and commissioning after maintenance.
4. Production Planning & Reporting
Achieve daily production targets as per the production plan.
Maintain shift-wise production logs and operational records.
Prepare daily reports on:
o Production
o Mill Performance
o Specific Power Consumption
o Equipment Availability
o Process Deviations
Ensure effective shift handover with complete operational updates.
Record corrective and preventive actions for continuous improvement.
5. Safety, Environment & Compliance
Ensure compliance with plant SOPs, PTW system, and safety procedures.
Maintain excellent housekeeping in operational areas.
Ensure compliance with statutory and environmental norms related to dust emissions and pollution control.
Participate in safety audits, toolbox talks, emergency drills, and risk assessments.
Report unsafe conditions, unsafe acts, and near-miss incidents.
Promote a strong safety culture within the department.
6. Team Coordination & Leadership
Guide and supervise CCR Operators, Field Operators, and technicians during shifts.
Allocate operational responsibilities to shift personnel.
Provide technical guidance and on-the-job training to junior team members.
Coordinate effectively with Production, Quality, Mechanical, Electrical, and E&I departments.
Support implementation of operational excellence and continuous improvement initiatives.
KRAs (Key Result Areas)
1. Operational Excellence
Stable operation of VRM and Cement Mill.
Achievement of planned production targets.
Maximum equipment availability.
Minimum operational interruptions.
2. Process Efficiency
Reduction in specific power consumption.
Improved grinding efficiency.
Optimized separator performance.
Increased mill productivity.
3. Product Quality
Consistent achievement of:
o Blaine
o Residue
o Cement Fineness
o Strength Parameters
Effective coordination with the Quality Control Department.
4. Maintenance Effectiveness
Timely identification of equipment abnormalities.
Effective coordination during shutdowns.
Reduction in downtime.
Improved equipment reliability.
5. Safety & Compliance
Zero Lost Time Injuries (LTI).
Compliance with statutory and company safety standards.
Adherence to environmental regulations.
Excellent housekeeping standards.
Technical Skills Required
Strong hands-on experience in VRM and Cement Mill operations.
Sound knowledge of cement grinding process and process optimization.
Expertise in CCR/DCS operation and process monitoring.
Good understanding of:
o Separator optimization
o Grinding aids
o Mill hydraulics
o Lubrication systems
o Gearbox operation
o Process interlocks
o Alarm management
Knowledge of cement quality parameters including Blaine, residue, and strength.
Ability to analyze process trends and implement corrective actions.
Knowledge of energy conservation and cost optimization.
Working knowledge of SAP/ERP and MS Excel will be an added advantage.
Behavioral Competencies
Strong analytical and troubleshooting skills.
Excellent problem-solving ability.
Leadership and team management skills.
Effective communication and interpersonal skills.
Cross-functional coordination.
Decision-making under production pressure.
Ownership and accountability.
Continuous improvement mindset.
Strong commitment to safety and operational excellence.
Ability to work in rotational shifts.