JOB DESCRIPTION - ANODIZING & SURFACE TREATMENT OPERATIONS

MIL - Metal Fabrication Unit

Thenepalle

Job Title

Assistant Manager / Deputy Manager / Manager - Anodizing & Surface Treatment Operations

Department

Manufacturing Operations - Surface Treatment

Reports To

Plant Head / General Manager - Operations

Direct Reports

Shift Chemists, Anodizing Operators, ETP Operators, Lab Technicians

Location

Plant - Puthalapattu, Chittoor, Andhra Pradesh

Plant Configuration

22-Tank Anodizing Line, 20 MT/Day Capacity

Employment Type

Full time, Permanent

Grade/Band

M08-M6A (as per company grading structure)

Position Objective

To establish, stabilize, and manage the complete anodizing and surface treatment operations for a 22-tank anodizing line producing solar-grade aluminum frames at 20 MT/day capacity. The role holder will commission the anodizing line, establish chemical process controls, build and train the operations team, manage ETP/utilities compliance, and deliver consistently anodized profiles meeting Tier-1 solar customer quality standards for Motherson and Vikram Solar.

Core Responsibilities

A. Anodizing Process Management

- Own end-to-end anodizing process: degreasing, alkaline etching, desmutting, anodizing, sealing, and all intermediate rinses across 22 tanks
- Establish and maintain precise chemical concentration targets for each tank through systematic titration and lab analysis
- Control anodizing voltage, current density, and bath temperature to achieve consistent oxide film thickness (15-25 microns per customer specification)
- Manage process chemistry for sulphuric acid-based anodizing including acid concentration, aluminum content control, and contamination monitoring
- Achieve first-pass yield 95% and maintain colour consistency where applicable
- Develop and implement process parameter windows (control limits) for each tank in the line

B. Chemical Handling & Laboratory Operations

- Manage handling, storage, dosing, and replenishment of sulphuric acid, caustic soda, nitric acid, sealant chemicals, and proprietary additives
- Establish titration protocols and daily/shift lab testing schedules for all critical tanks
- Monitor and control chemical concentration, pH, conductivity, and dissolved aluminum across the process
- Implement chemical consumption tracking and cost optimization without compromising process quality
- Ensure proper chemical compatibility, segregation in storage, and MSDS availability at all handling points

C. Utilities & Environmental Systems

- Directly manage ETP (Effluent Treatment Plant) operations: neutralization, flocculation, sludge dewatering, and discharge compliance
- Oversee RO (Reverse Osmosis) plant and DM (Demineralized) water plant to ensure rinse water quality and process water standards
- Maintain water balance across the anodizing line-minimize freshwater consumption and maximize water recycling
- Manage chemical filtration systems, sludge disposal (as per hazardous waste regulations), and waste manifests
- Ensure full compliance with CPCB/SPCB norms and support environmental audit readiness

D. Rework & Rejection Management

- Analyze every anodizing rejection systematically: identify root cause (chemical, handling, pre-treatment, or extrusion-related)




- Manage controlled stripping and rework processes without damaging base profile dimensions
- Track rework volume, stripping chemical consumption, and yield recovery metrics
- Implement process corrections to prevent repeat defects and reduce rework below 3%

E. Shot Blasting Operations

- Oversee shot blasting preparation where required for specific surface finish specifications
- Control shot blasting parameters (media type, intensity, coverage) for consistent surface preparation
- Prevent over-blasting, under-blasting, and media contamination defects

F. Quality Assurance

- Ensure anodizing coating thickness compliance using eddy current / coating thickness gauges on every load
- Verify adhesion (tape test / boiling water test), corrosion resistance (salt spray / acetic acid test), and sealing quality
- Drive zero tolerance for surface finish defects: staining, burning, patchiness, discoloration, water marks, chemical contamination, handling scratches post-anodizing
- Support customer sample approvals, first-article inspection, and ongoing PPAP maintenance

G. Safety & EHS Compliance

- Establish and enforce acid handling SOPs: PPE requirements (acid-resistant suits, face shields, chemical gloves), spill containment, emergency eyewash/shower stations
- Conduct regular hazardous chemical safety training for all anodizing personnel
- Maintain emergency response protocols for acid spills, chemical burns, and fume exposure incidents
- Ensure full compliance with Factories Act, environmental regulations, and customer EHS audit requirements

H. Production Management & Systems

- Drive throughput optimization to achieve 20 MT/day rated capacity within 6 months of commissioning
- Manage jig design, loading density, and cycle time optimization for maximum rack utilization
- Establish OEE tracking, shift management protocols, and production planning adherence
- Deploy and sustain 5S, visual management, and standard work across the anodizing shop

I. Leadership & Team Building

- Build the anodizing team from scratch: hire and train shift chemists, operators, ETP operators, and lab technicians
- Create comprehensive training modules covering anodizing chemistry fundamentals for all operators
- Independently manage customer audits and qualification processes
- Support plant commissioning: tank installation validation, chemical charging, process proving, and customer sample approvals

Key Performance Indicators (KPIs)

KPI

Target

Measurement

First-Pass Yield

≥95%

Daily

Rework Rate

3%

Weekly

Throughput

≥20 MT/day (post stabilization)

Daily

Coating Thickness Compliance

100% within spec

Every load

Chemical Cost per MT

Within budget ±5%

Monthly

ETP Discharge Compliance

100% within CPCB norms

Daily

Water Consumption per MT

Benchmark - 10% year-on-year

Monthly

Safety Incidents





Zero chemical incidents

Monthly

Customer Audit Score

≥85%

Per audit

SOP Completion

100% within 6 months

Milestone

Candidate Profile & Qualifications

Education

- B.E. / B.Tech in Chemical Engineering, Metallurgical Engineering, or Electrochemistry (mandatory)
- B.Sc. Chemistry with extensive anodizing line experience (acceptable for AM level)
- M.Tech in Surface Engineering / Corrosion Science or MBA in Operations (preferred)

Certifications (Preferred)

- NACE / SSPC Coating Inspector certification
- Six Sigma Green Belt
- ISO 14001 / ISO 45001 Internal Auditor
- Hazardous Chemical Handling / HAZMAT certification

Experience

- 8-15 years of progressive experience in aluminum anodizing / surface treatment operations (mandatory)
- Minimum 2-3 years in a supervisory or managerial capacity independently running an anodizing line
- Direct experience with multi-tank (15+ tank) sulphuric acid anodizing lines
- Greenfield setup or major line commissioning experience is a strong advantage
- ETP/RO/DM plant hands-on management experience (mandatory, not just oversight)

Must-Have Industry Background

- Aluminum anodizing for solar frames, architectural profiles, or industrial applications
- Multi-tank continuous/batch anodizing line operations (not small job-shop anodizing)

Preferred Source Companies

- Jindal Aluminium (anodizing division), Hindalco downstream units
- Alom Extrusions, Maan Aluminium, Salman Group
- SAF Aluminium (anodizing specialist), Bhoruka Extrusions
- Aluwind Architectural Products, Alstrong Enterprises
- Any Tier-1 solar frame manufacturer with in-house anodizing

Technical Competency Matrix

Competency

Required Level

Assessment

Sulphuric Acid Anodizing Process Control

Expert

Technical Interview

Chemical Titration & Lab Analysis

Expert

Practical Test

Pre-treatment (Etching/Desmutting)

Expert

Process Walk-through

ETP / RO / DM Plant Operations

Advanced

Case Study

Coating Thickness & Sealing Quality

Expert

Technical Interview

Defect Analysis (Staining/Burning/Patchiness)

Expert

Photo Analysis Test

Hazardous Chemical Safety / EHS

Advanced

Behavioral Interview

Rework/Stripping Process

Advanced

Technical Interview

Environmental Compliance (CPCB/SPCB)

Intermediate+

Regulatory Knowledge

Water Balance & Utility Optimization

Intermediate+

Case Study

Behavioral Competencies

Competency

Expected Behavior

Process Discipline

Maintains chemical process parameters with zero deviation treats specification limits as inviolable, not guidelines

Safety-First Mindset

Proactively identifies chemical hazards before incidents occur never compromises safety for throughput

Analytical Rigor

Relies on data (titration, thickness, conductivity) for every decision rejects intuition-based chemical management

Environmental Stewardship

Takes personal ownership of ETP compliance and waste management as a core responsibility, not an afterthought

Institution Builder

Creates SOPs, training materials, and control charts that make the process person-independent

Composure Under Chemical Emergencies

Remains calm and follows protocol during acid spills, bath contamination, or ETP upsets never freezes

📌 Deputy Manager - Production (India)
🏢 Amara Raja Group
📍 India