Sectional Head, Instrumentation

Responsibilities

1. 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.
  

2. 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.
  

3. 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.
  

4. 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.
  

5. 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).
  

6. Team Leadership & Safety

• 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.
  

Benefits

• Private Health Insurance
  
• Paid Time Off
  
• Training and Development