AH Process

Job Purpose

Drive optimal performance on Extrusion presses, achieving production and recovery targets with precision in quality, all while maintaining cost efficiencies. Spearhead equipment projects, ensuring seamless execution, optimal resource utilization, safety, and upholding the highest quality standards.

Job Context & Major Challenges

Job Context: Hindalco is a leading producer of aluminum in the country. Extrusion process is very versatile & cost-effective metal forming process. The Silvassa Hindalco Extrusion section is new location and dedicated for B&C market which requires the low product cost with the utmost quality which is only possible with working of high-end press along with downstream process. Hindalco Industries Ltd. Is the Metals Flagship of Aditya Birla Group.

Hindalco Industries Ltd. Silvassa Extrusion plant aims to develop a one-of-a-kind Manufacturing Unit that will be highly automated to bring superior quality and consistency. Our staffing philosophy is to create a World Class Experience by partnering with best-in-class professionals who are values-driven, growth driven, learning agile, digitally savvy, self-driven, collaborative, and technically best, to consistently deliver superior and outstanding business results.

Job Challenges: Optimize production across three Extrusion presses.

• Achieve world-class efficiency and product qualification.
• Maximize press utilization to hit 34 KT/annum targets.
• Deliver consistent quality with 80% recovery for critical products.
• Guarantee timely, complete product deliveries.
• Manage tooling and material costs within set budgets.
• Finalize projects on time and on budget in the Extrusion area.
• Establish and standardize compliant systems and documentation.
• Regulate inventory through efficient scrap management.
• Re-engineer and reclaim rejected extrusions.
• Prioritize safety for all operational staff.
  
  

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)

KRA1 1. Operation

To ensure the planned production and control the critical parameters to achieve quality products as per set production target of 34000 MT/ annum on three Extrusion presses 1. Operation

To ensure the planned production and control the critical parameters to achieve quality products as per set production target of 34000 MT/ annum on three Extrusion presses

• Stabilization and production from state- of-art equipment with highly automation.
• Product & Process qualification.
• Implement operation activities as per standard Operating procedure.
• Execution of Quality, Recovery and delivery of targets and products.
• Review and revise process parameters to achieve world class product with best productivity.
• To execute availability of equipment to meet the production targets.
• To implement and ensure production with safe working conditions.
  
  

KRA10 10. Data Analytics and Technology Integration Utilize data-driven insights to streamline operations and integrate emerging technologies that enhance productivity and efficiency across Extrusion presses.

KRA2 2. Stores, Cost Reduction & Profitability

To ensure Stores materials and press tooling Consumption within the P&B Target to meet the P&B target of 34000 MT on all the Extrusion presses 2. Stores, Cost Reduction & Profitability

To ensure Stores materials and press tooling Consumption within the P&B Target to meet the P&B target of 34000 MT on all the Extrusion presses ? Preparation of the Budget for stores consumables & Extrusion press.

• To ensure the consumption of materials within the budgetary target & develop vendors.
• Maintain the press tooling as per the requirement through new procurement within the budgeted target.
• Ensure Development and Repair of press tooling through coordination with External suppliers.
• Identification & elimination of non-value adding activities
• To monitor power consumption of presses and make action plan to reduce it.
  
  

KRA3 3. NRT of Equipment

To ensure NRT of presses within the P&B Target to meet the P&B target of 34000 MT on all the Extrusion presses ? Identify chronic and sporadic problem of the press.

• Make action plan to take corrective action to improve presses uptime for more production.
  
  

KRA4 4. Project & various developmental activities

To ensure Projects & developmental activities

Ongoing and ensure their implementation of the Extrusion press area. ? To identify and ensure the implementation of developmental activities for improvement in production, Recovery, delivery, productivity etc.

• To Estimate & prepare the Capex proposals for the projects and ensure its implementation.
  
  

KRA5 5. Quality Management, People Management, Development & Training

Implement quality system plan for human resource development and process improvement. Ensure development of sub-ordinates and workforce (staff and workmen) on Extrusion presses for productivity increase. Optimum utilization of manpower at various work centers to improve the bottom line. ? Implement standard operating practice and quality plan

• Support in development of new product on presses and development of quality plan.
• To implement proper deployment of manpower at various work centers to achieve stretched production targets.
• Review and monitoring grievance readdress to ensure harmonious employee relation.
• Facilitating the use of skill index and skill gap to monitor the growth of subordinates & workmen.
• Timely communication of policies, vision, mission & strategies.
  
  

KRA6 6. Management of Press Documents, IMS & MIS activities

Ensure Management/ documentation / compilation of related activities of IMS &MIS activities. ? Through the interactions with OEMs and design teams document the operation system – Manuals/ SOPs / Practices for the Plant Operation

• Implementation these systems during ramp up and running of the plant.
• Documentation of development of system & compliance with IMS
• Completing timely preparation of MIS of all presses
  
  

KRA7 7. Safety, Environment &System Management

Ensure& Implement safe work culture at working place. ? Ensure implementation of use of PPE by all at work place

• Ensure to create awareness among all to achieve Zero accident
• Periodic counseling of employees
• Drive sustainability initiatives to reduce the organization’s environmental footprint.
• Monitor and report on sustainability metrics and progress toward sustainability goals.
  
  

KRA8 8. Data Analytics and Technology Integration ? Utilize data analytics tools to derive insights and drive data-driven decision-making.

• Explore the integration of Industry 4.0 technologies such as IoT and AI for process optimization.
• Implement digital manufacturing solutions for real-time monitoring and control of production processes.
• Ensure data security and privacy in production and operations systems.
  
  

KRA9 9. Strategic Planning and Leadership & Customer Engagement and Satisfaction ? Contribute to the development of the organization’s long-term vision and goals.

• Mentor and develop team members to enhance their skills and capabilities.
• Foster innovation and creativity in production and operations processes.
• Evaluate and recommend emerging technologies and trends for adoption.
  
  

Strategic Planning and Leadership: Devise strategic initiatives aligned with organizational goals, leading the team with a forward-thinking approach to achieve benchmarks and foster growth. &

• Collaborate with sales and marketing teams to gauge customer feedback and ensure the delivered products meet or exceed customer expectations, building lasting relationships and trust.

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