Business

Metals

Unit

Downstream Kuppam Extrusion

Location

Kuppam

Poornata Position Number of the job

Reports To Poornata Position No

Poornata Position Title of the job

AH Fabrication

Reports To Poornata Position Title

SH Fabrication

Function

Manufacturing operations

Reports To Function

Manufacturing operations

Department

Production

Reports To Department

Production

Date of Last Updation/Approval

- Job Purpose

Monitoring Fabrication department’s production activities for meeting specifications and deadlines of internal & external customers by liaising with peer’s departments and Fabrication 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

MS

LMS

Contract

Total

3

36

152

191

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

Fabrication

9.3

18

2049

Titan, PT Hitachi, Aerocompact, Hero, Ecoppia, Corob

4800

Formworks, Solar, Automotive, Industrial

50% 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 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.

Job Challenges

- Maintaining Productivity, Quality for delivering targeted KPI’s due to change in crew due to wide fluctuations in orders which are project based and majority of workforce is off roll.
- 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 workplace 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 fabrication 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 NAV(net added value) per man hour by Avoiding Non-value added activities by monitoring production on daily basis and effective planning by co-ordination with PPIC & sales

Monitor process rejections in fabrication processes on daily basis Production Planning and maintaining documents
- Preparing the daily plan based on available orders and machines with coordinating with sales and 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, Anodizing, Powder coating, packing and dispatch etc
- Calculating takt & leading time for the processes and customers




- 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 fabrication processes

Indents making
- Daily tracking and maintaining minimum stocks by Ordering the regular consumables and fasteners based on available orders and forecasts
- Getting quotes for new projects or existing process to reduce delivery times and savings to organization

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
- Internal IATF auditing other depts

Stock Inventory and accountability of Outsourcing (Servicing)
- Verify consumables, aluminum profile, equipment, and job work stock
- Maintaining less than 30MT WIP
- Consolidating all inward and outward material
- Outsourcing which is not feasible or capable
- Preplanning & ensuring with on time material supply (Inward & Outward)
- Ensuring quality products are supplying and delivering back the same
- Record and closing of PO’s on right time

Meetings and troubleshooting’s
- 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
- 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
- Setting up of current goals and challenges
- Job Purpose of Direct Reports:

Position Title

Job Purpose Position No.

Shift Supervisor Achieving shift targets by monitoring shift production and Line inspection

Supervisor - SMS

Assembly & packing of SMS and Fabrication orders

- Relationships:

Relationship Type (Internal or External) Frequency & Nature

SH Fabrication Daily - Seeking advice, consultation, and approvals.

AH Extrusion

Daily – Raw material requirements

AH Packing

Daily – Packing related services

AH Dispatch

Daily – Dispatch related services

AH PPIC

Daily – Planning activities

AH SCM

Daily – Procurement of consumables, outsourcing,

AH QA

Daily – Process audits, Customer related meetings

AH PD

Daily – New production development

AH Anodizing

Daily – Raw material requirements

AH Powder coating

Daily – Raw material requirements

AH Finance

Daily – For Indent creation

AH HSE

Daily - Safety

External Customer

Need basis – Customer complaints, technical meetings, new development

External Suppliers

Need basis – Procurements.

- Organizational Relationships:

Position that It reports into Position and its peers (Nop = ) Position/s that reports into (Nop = )

SH fabrication

AH PPIC

AH Extrusion

AH Die shop

AH Anodizing

AH Powder coating

AH Packing

AH Dispatch

AH Store

AH SCM

AH Maintenance

AH PD

AH QA

AH Projects

AH HSE

Shift Supervisors

Supervisor – SMS and Fab packing

Declaration: This is a true reflection of the position AH Fabrication

Job Holder

Reports to Manager

Name

Date of Entry / Approval

📌 AH Fabrication (Andhra Pradesh)
🏢 Aditya Birla Group
📍 Andhra Pradesh