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• Job Purpose
  
  

Monitoring Powder coating department’s Production & Process activities for meeting specifications and deadlines of internal & external customers by liaising with peer’s departments, Lab Chemists and Shift Supervisors.

• Dimensions:
  
  

Business/SBU/Unit Revenue

403 crores.

Business Workforce Number

Unit Workforce Number

MS

LMS

Workmen

Contract

Total

80

261

2

336

679

Function Workforce Number

MS

LMS

Contract

Total

19

192

293

504

Department Workforce Number

Department

MS

LMS

Contract

Total

Powder coating

1

7

19

27

Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter

Department

Budget (Cr)

Revenue (Cr)

Volume(T)

Major Customers

Annual Capacity(T)

Geography/Markets

Powder coating

5.2

5.8

816

Schueco, Alumax, Titan, Olympic, Ecoppia, Corob

6250

Formworks, Industrial, B & C

20% Export business

• Job Context & Major Challenges:
  
  

Job Context

The global aluminum market is valued at USD 87.84 billion in 2021 and is expected to grow 7.5 % (CAGR) from 2022 to 2030. Increase in demand for lightweight and durable extruded products is driving the growth. Top aluminum extruders are investing and creating tough competition.

Hindalco Industries Limited have acquired the extrusion business of SAPA located at Kuppam, Andhra Pradesh with effect from 01 Feb 2022 through Business Transfer Agreement

This plant is first of its kind, across the globe to have mill finish, anodized, powder coated, fabricated products manufactured under one roof. The profiles developed and manufactured are highly complex in nature, having critical die designs, challenging operations, involve highly skilled technicians, special machinery, and processes. This unit has two 8-inch press with a capacity of 16,000 TPA, anodizing 2500 TPA, powder coating 3200 TPA along with various fabrication machinery like manual & robotic welding, CNC cutting & machining centers, Flaring & collaring, assembly lines serving for Building & Construction (25%), Industrial (40%), Exports (25%) Automotive (7%), and Solar segments (3%).

The unit is increasing its business in automated warehouse system, premium anodizing finish products (exports), Solar energy and automotive (domestic) segments by increasing utilization of existing facility with additional shifts for continuous operation, setting up new fabrication facility, additional anodizing tanks and a brand-new extrusion press.

Kuppam Powder coating adds Value on Extruded Aluminium profiles by giving decorative finish to Aluminium with wide range of colors for Automotive, Construction, Solar and Industrial segments.

Kuppam powder coating equipped with Gema’s Electrostatic spraying guns technology which can coat any color in the universal with 260T per month capacity.

Job Challenges

• Achieving efficiencies & productivity in Powder coating to deliver targeted cost of production.
• Frequent Powder changeovers due to low volume orders.
• Key Result Areas/Accountabilities:
  
  

Key Result Areas/Accountabilities

Supporting Actions

Safety - To build a strong Safety culture in the plant with the objective to make this factory ZERO HARM and to provide a safe working environment to employees, contractors

Monitor, Review & update the fabrication processes regularly for safe & enviro-friendly operations.

Attending safety trainings and cascading the learnings to downstream.

Having frequent rounds in shop floor to identify & report Near misses and potential incidents together.

Walk to shop floor, observe safety behaviors of employees, and communicate to them and upload with action plan in Enablon App.

Machine guarding - List & Observe all equipment’s of plant and ensure to have safeguarding to all equipment’s along with core team

Focus on sustainability of Value addition dept

Drive improvement that light of highly illuminating sheet to be provided and all unwanted lights off in day light and machines are off when not in use and all are identified through line audit in each shift by supervisor/engineer

There shouldn’t be single point in air leakage and frequent change of compressed air pipes or alteration to aluminium pipes to avoid pipe damages/breakages

Conducting 5s trainings and auditing 5s zones

Improve Profitability and Cash Flows

Improve Man per hour & Effective utilization of machines and manpower

Effective utilization Powder coating by monitoring production on daily basis and effective planning by co-ordination with PPIC & sales

Monitor process rejections in Powder coating processes on daily basis

Production Planning

Preparing the daily plan based on available orders and coordinating with planning team

Ensuring the raw materials, consumables, fasteners on time to the production

Analysis of daily production and tracking & follow ups the same.

Requesting to internal teams to clear for incoming orders, drawings, inspection reports and addition requirements based on customer feedback and needs

Anticipate team work to finish the production on given time.

Responsible for safety measures, process deviations and change in concurrent plan of production

Discussion with all depts to clear on time internal process issues with die shop, extrusion, Fabrication, Anodizing, packing and dispatch etc

Production Documents

Preparing and analyzing the daily production data and KPI reports with appropriate targets to the line.

Reviewing the OEE.

Tracking and updating all the orders

Records of powder consumption & Chemical consumption

Scrap monitoring

Internal Audits

To Ensure all the documentations required for audit are in place related to safety, production, and quality

Maintain all records, proofs and actions for refreshment trainings and closing NCs

Quality checks

Interval auditing of lines and ensuring right parts are produced as per color & Customer

Stock Inventory and accountability

Verify consumables, aluminum profile, equipment and job work stock

Maintaining less than 30MT WIP

Consolidating all inward and outward material

Meetings

To review production plan execution with supervisor

To review production challenges with boss for facilitating needs of urgency

Ensure no deviation in flow of achieving production and delivery with internally related depts

Timing and troubleshooting

Assuring no bottleneck ness, increased productivity, Poka-yoke and contingency plan

Performance feedback

Feedback and Evaluation of performances of supervisors

Valuation and finalization of peak performances of operators & On-Roll Employees

Setting up of new goals and challenges towards the goal

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