Business

Metals Corporate

Unit

Downstream Kuppam Extrusion

Location

Hindalco, Kuppam

Poornata Position Number of the job

Reports To Poornata Position No

Poornata Position Title of the job

AH Mechanical Maintenance Value Add

Reports To Poornata Position Title

DH Mechanical Maintenance

Function

Engg, Main & Utility Services

Reports To Function

Engineering

Department

Engineering

Reports To Department

Engineering

Date of Last Updation/Approval

- Job Purpose

To plan, coordinate and carry out maintenance activities of Value add (Anodizing, Powder coating, Fabrication) equipment’s, Material handling equipment, Post extrusion, ware house. To plan for continual improvement, redesigning systems and practices to maximize availability and enhance reliability of plant and equipment within budgeted cost. To execute all capital expenditure projects keeping the overall project cost and time within budget. To Coordinate WCM activities and Integrated Management System - ISO 9001,ISO-14001 and OHSAS-18001 of the Mechanical maintenance department for the overall manufacturing excellence . To Plan and implement effective spare parts management system in coordination with supply chain department
- Dimensions:

Business/SBU/Unit Revenue 403 Cr

Business Workforce Number

Unit Workforce Number

MS

LMS

Workmen

Contract

Total

80

261

2

336

679

Function Workforce Number

MS

LMS

Contract

Total

19

26

7

52

Department Workforce Number

MS

LMS

Contract

Total

3

13

0

16

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

- Job Context & Major Challenges:

Job Context The global Aluminium 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. 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 design, challenging operations, involve highly skilled technicians, special machinery and processes. This unit has two 8-inch press with a capacity of 16KT per annum, anodizing 2.5 KT per annum, powder coating 3.2KT per annum along with various fabrication machinery like manual and robotic welding, CNC cutting & machining centers, Flaring & collaring, assembly lines serving for Building & construction (38%) , industrial (41%), Exports (11%), Automotive (7%), and solar segments (3%).

This 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, setting up new fabrication facility, additional anodizing tanks and a brand-new extrusion press.

To maintain the health of old equipment’s by timely, planned and systematic maintenance. Ensure the availability and reliability of equipment within the P&B; target. Enhance health and reliability of equipment by suitable technical / design modifications Study and train the staff and operatives on the complex hydraulic system of the Anodizing , powder coating and various fabrication machines to independently manage breakdowns in shifts Conceive,



acquire and assimilate new technologies in the area of engineering and maintenance Consistent cost reduction initiatives on all fronts viz. maintenance cost, power consumption (resource conservation) ,import substitution etc and identifying new areas for cost reduction to sustain cost competitiveness To support production centers in minimizing small stops and to improve productivity Minimize turn-around time for the shutdown maintenance of Control the inventory of Mechanical maintenance stores under optimum level to bring down inventory carrying cost.

Vendor development for cost competitiveness and import substitution Motivate people to participate actively in WCM activities. Check and approve design and drawings of spares and new construction.To train the maintenance crew

Job Challenges

Enhancing skill of workmen and proficiencies of maintenance team members.

Manpower retention and hiring – Due to location constraint

Spare parts management due to lack of ERP system

- Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions Plan, co-ordinate and implement maintenance activities to maximize availability of plant / equipment / machineries at minimal cost. Criticality ranking of all equipment and machineries. Classify critical & non-critical equipment Maintenance decision-making by fixing suitable maintenance strategies / frequencies based on relevant data. Preparation of preventive maintenance master schedule for equipment & machinery.

Facilitate Computerized Maintenance Management

System for Planned/Predictive/Corrective and Breakdown Maintenance. Ensure execution of maintenance without slippage to maximize availability. Ensure maintenance of equipment history (system based) for all major /critical equipment. Analysis of breakdowns followed by corrective and preventive actions Technical / Design modifications to improve the level of reliability and availability of plant and equipment.

Ensure Condition

Monitoring of critical equipment. Spare parts management Calculation and dissemination of Maintenance Performance Indices Maintain the plant and within planned breakdown (Avg./month)

R & M Cost

Assist DH in preparation of budget and ensure spending within approved plan Develop vendor for better service at reduced cost. Analyze variations and take corrective steps to ensure R&M; cost within budget Vendor development for cost effective spares and for import substitution.

Effectively

Negotiate with vendors for better cost advantage and achieving the organizational target

Spare parts management

Spares management with the help of supply chain department Develop new vendors. Identify spares for new equipment. Review bin items and take corrective actions. Import substitution

Statutory requirements

Ensure Mechanical system meets all statutory requirements as envisaged in factories act and rules. All lifting tackles are maintained as per Legal metrology rules/acts.

Product Quality To ensure the calibration of all the mechanical related gauges and instruments. Maintain all heat treatment furnaces and ensure proper operation to ensure product quality.



Ensure operation of all equipment at the desired operation parameters

Projects / Developmental Activities

Carry out process developments for production increase and reduction in raw material / energy consumption. Preparation of RFA s as per approved Capex plan Freeze the technical specification of the equipments Vendor hunting Supplier/ Vendor visits Planning, procuring, erection and commissioning of Capex projects. Implementation and monitoring of Setting related aspects related with projects Ensure the work permit system Ensure the contract workers safety especially working at heights for Medical check up.

Ensure the safety practices in materials handling, availability and usage of PPE s for work Implement the recommendations of the technical audits carried out by any third party

IMS System Upkeep To maintain all the documents/ records of IMS for mechanical maintenance department. To amend necessary changes in documents, procedure and others if required. Conduct regular audits Close and take corrective action for all the NCR s during external or internal audits

SAFETY

Periodical assessment Potential Risk and implementation of risk mitigation plans as per Corporate Guidelines Ensure statutory testing and certification of lifting equipment and lifting tackles, pressure vessels etc as per plan. Building stability evaluation and certification Ultrasonic examination of lifting tackles / crane hooks Ensure Legal and statutory compliance as applicable as per Corporate Guidelines Implement the decisions of EOH & S committee and other safety committees. Work towards achieving zero accident frequency rate and zero severity rate.

Conduct SAE (Safe Attitude Encouragement) rounds to monitor and eliminate unsafe acts and conditions to ensure zero accidents, zero incidents and zero injuries Ensure 100 % compliance to safety guidelines and other statutory requirements. Conduct JSA and share results across the units. Monitor and eliminate the unsafe acts and conditions for zero accidents and incidents in the Dept

- Job Purpose of Direct Reports:

Position Title

Job Purpose Position No.

AH Extrusion

- Relationships:

Relationship Type (Internal or External) Frequency & Nature FH Engineering For getting the feedback on performance of the equipment and getting the equipment for maintenance (Daily) For appraising the status of maintenance and project activities RFA approval clarifications, Interaction on IMS, WCM activities, Capex Projects overall status reporting, Monthly Works report submission (Monthly/Weekly/Daily as applicable)

Head: Mechanical For appraising the status of maintenance, discussion, Resource Requirements, Project status Updating & its Review (Daily)

Head : Projects & Materials /Finance

Project discussion, (As and when required)

Maintenance team For appraising the status of maintenance & project activities (Daily)

SCM team For material follow up and procurement

- Organizational Relationships:

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

FH Engineering SH Mechanical - Extrusion

SH Electrical – Plant

SH Electrical – Power & Utility

DH Production

SH Safety

SH Value add

DH Die shop

SH Quality Assurance

SH Finance & Accounts

SH packing

SH Dispatch

SH SCM

DH HR

DH Planning

SH IT

SH Projects

AH Mechanical Maintenance

Declaration: This is a true reflection of the position – SH Mechanical Value Add

Job Holder

Reports to Manager

Name

Date of Entry / Approval

📌 AH Mechanical Maintenance (Andhra Pradesh)
🏢 Aditya Birla Group
📍 Andhra Pradesh