Business

Metals

Unit

Downstream Kuppam Extrusion

Location

Kuppam, Andhra Pradesh

Poornata Position Number of the job

00194444

Reports To Poornata Position No

00194443

Poornata Position Title of the job

AH PD Feasibility

Reports To Poornata Position Title

SH PD

Function

Quality and Technical Services

Reports To Function

Quality & PD

Department

Quality

Reports To Department

Downstream Kuppam Extrusion

Date of Last Updation/Approval

- Job Purpose

Perform design review based on feasibility study, inputs provided from customer and sales team for new products along with CFT and provide the feasibility reports to sales team and RFQ (costing input) report to finance team .
- 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

Workmen

Contract

Total

8

25

0

10

43

Department Workforce Number

MS

LMS

Workmen

Contract

Total

4

2

0

0

6

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

Number of new dies per year -100 dies

Volume due to new development dies – 1000 TPA

Cadres to Automotive, B&C;, Industrial, EV, Solar applications.

- 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.

More new products will be developed in all segments, Electrical Vehicle market is evolving growth, automotive segment is predicted to grow, increased robotic applications, upgradation in technology causing current product developments. In order to meet the customer requirements new product development function is necessary.

Job Challenges: Major challenge is meeting customer requirements with stringent tolerances beyond the standard norms, setting up process during development based on customer specific requirements, Customer demanding on reduction in development lead time.

- Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

Product Feasibility

- Preparing the feasibility study with collaboration with plant core team.
- Ensuring customer provided drawings, related specifications along with “Authorize to quote” form.
- Analysis the drawings and preparing the feasibility study report with standard format.
- Preparing design changes and proposal for different concepts for customer profile to suit to the manufacturing feasibility and discuss with customer for implementation during development.
- Sketch outline designs and using CAD programs to create detailed design and specifications.
- Replicate physical sample given by customer into auto CAD if drawings are not available.
- Responsible as drawing checker with complete dimensional data for engineering or manufacturing purposes using GD&T; and reviews for accuracy, completeness and conformance to drafting, applicable design, component weights and system standards.
- Discussion with die suppliers and to get offer & guarantee for critical profiles to perform feasibility study.
- Feasibility study will be done and forwarded to Sales team in the same form that has section “Enquiry review”
- Comparing existing past troubles for effective implementation of new products without any troubles.

Request for a Quote (RFQ)

- Preparing the RFQ input with technical details providing by sales team for Extrusion, Anodizing & Powder coating.
- Collaborate with fabrication and packing team for the RFQ inputs.
- Collaborate with SCM for new requirement powder details, dies and to get supplier quote for RFQ.
- To provide RFQ inputs to costing team on request from sales representatives.

Customer Audits

- To Ensure all the documentations required for audit are in place related to Feasibility & RFQ.




- Maintaining documents, drawings and other records for all projects.

Counter Drawing

- Providing the inputs along with feasibility report to team member to prepare counter drawings.

ECN – Engineering Change

- To review the changes request from customer, based on changes RFQ preparing & submission to costing team within timeline.

Customer Interface

- Technical discussion with customer by collaborating with sales team for further details if any required for new enquiry related.
- Job Purpose of Direct Reports:

Position Title

Job Purpose Position No.

- Relationships

Relationship Type (Internal or External) Frequency & Nature

Die Shop

- Coordinate for current enquires and manufacturing capability of new products for every new enquiry.

Extrusion
- Coordinate for new enquires and manufacturing capability of new products for every recent enquiry.

Quality
- Discussion related to new enquires customer requirements, product application and customer communications.

Fabrication
- Discussion related to new enquires and manufacturing capability for every new enquiry.
- To share the project details along with drawings to prepare the fabrication RFQ.
- Collecting the fabrication RFQ inputs.

Anodizing & Powder Coating
- Coordinate for new enquires product finish requirements and possibility of manufacturing for every new enquiry.

Packing & Dispatch
- Coordinate for new enquires packing requirements for every new enquiry.
- To share the project details along with drawings to prepare the packing RFQ.
- Collecting the packing RFQ inputs.

SCM
- Discussion with new requirement powder details, dies and to get supplier quote for RFQ.

Finance
- Preparing the RFQ inputs from sales & plant & compiling the requirements from relevant parties of RFQ & documents submission to Finance for every new enquiry.

Sales
- Discussion with new product development and communicating the possibilities of manufacturing.
- Updating the feasibility study, Die cost details & RFQ for every new enquiry.
- To provide submitted RFQ list to sales team. We will follow and get to release the dies in continuously.
- Weekly meeting with sales team to review the feasibility status and monitor progress.

Die Suppliers
- Discussion related to new product development dies offer & dies guarantee.
- Organizational Relationships:

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

SH PD

AH PD Trial Plan

AH Die Shop

AH QA &CS; – Value Addition

AH QA & CS - Extrusion

AH Trial Planning

AH Inside Sales

AH External Sales

Nil

Declaration: This is a true reflection of the position AH PD – Feasibility

Job Holder

Reports to Manager

Name

Date of Entry / Approval

📌 AH PD Feasibility Study (Andhra Pradesh)
🏢 Aditya Birla Group
📍 Andhra Pradesh