DH Fab

Designation: Assistant General Manager

Location: India Andhra Pradesh Kuppam, Andhra Pradesh

Organization: Metals

Job Description:

Job Purpose

Leading, managing, and developing Value addition (Fabrication, Anodizing, Powder coating) departments to ensure them to achieves the highest possible standards of excellence in all its activities for meeting specifications and deadlines of internal & external customers while Enforcing Environmental policies, Safety - Health precautions and Quality Standards.

Also responsible for Capacity planning, People’s skill development, Outsourcing management and project management.

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 Fabrication adds Value on Extruded Aluminium profiles by performing processes like MIG welding, CNC Machining, Cutting, Punching, Forming, Printing, Threading & Assembly for Automotive, Formworks, Solar and Industrial segments. Kuppam Fabrication equipped with 8 Qualified welders, 3 & 4 Axis CNC Milling, Hydraulic and Mechanical Forming & Punching, External 4-start threading, Thermal drilling technologies and it can produce 300 to 400T per month with Rs. 520 NAV(net added value) per man hour.

Kuppam Anodizing and 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 Anodizing has special process called Brit dip, it gives silver finish to aluminium profiles which are widely used in shower cubicles, US based customer called Alumax imports these value-added aluminium profiles (45T per month) from Kuppam plant, apart from this Kuppam Anodizing plant equipped with Italtechno three rectifiers - 2 normal and 1 color which are capable to anodize Natural, bronze, champagne & Black colors with 196T per month capacity.

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:

1. Maintaining Productivity, Quality for delivering targeted NAV per capita due to fluctuations in product mix in Fabrication.

2. Achieving efficiencies & productivity in Anodizing & Powder coating to deliver targeted cost of production.

3. Talent retention especially in Fabrication due to wide fluctuations in orders which are project based and majority of workforce is off roll.

4. Developing of vendors for outsourcing due to capacity constraints and new requirements.

5. Developing new products and finding suitable technology meeting stagnant deadlines of automotive customers.

6. Motivating and Keeping morale high of employees.

Key Result Areas

KRA (Accountabilities) (Max 1325 Characters)

Supporting Actions (Max 1325 Characters)

KRA1

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 value addition 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

KRA2

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

KRA3

To develop a customer centric organization

Drive OTIF to the level of >/=99% by improving the planning and scheduling process. Reliability Roadmap to be reviewed & continuously upgraded

KRA4

Improve Profitability and Cash Flows

Improve NAV(net added value) per man hour by Avoiding Non-value added activities, Effective utilization of machines and man power

Effective utilization of Anodizing & Paint lines by monitoring production on daily basis and effective planning by co-ordination with PPIC & sales

Monitor process rejections in value addition processes on daily basis and take actions for

KRA5

To focus on operational efficiencies

continuous improvements - Monitor & update Safety, Quality & Processes for Safe & effective outcomes

Develop alternate chemical supplier, monitor chemical consumption on monthly basis to have better control

KRA6

People and process capability increase.

Training Man days on Fabrication processes and Fabrication feasibility study (PD)

Shillim cascading to down the line.

KRA7

Development of new Projects for Expanding capacity of Value Addition

Ensuring to submit new products Feasibility study to Finance on time with accurate data.

Building customer relationship at high level by delivering right products on time.