Job highlights

- Shift Chemists,Anodizing Operators,ETP Operators,Lab Technicians .
- 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 .
- Establish OEE tracking,shift management protocols,and production planning adherence .

- 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 accurate 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

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

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.

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