Job Description

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Job Purpose
Verifying quality control of incoming, in process and final inspection products in fabrication anodizing and Powder coating departments. Planning and implantation of quality assurance system activities for Kuppam plant including coordination with external agencies for third party inspection, certification, testing etc.
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.It is by maintaining the proper quality of products that Kuppam works can remain competitive in the market.
Job Challenges: Quality standard should meet the stiff requirement of automotive, exports, industrial and Building & Constructions customer requirements. Ensuring to meet the quality of dimensional accuracy, aesthetic, metallurgical and mechanical properties requirements play a key role in sustaining market share. Untrained contract manpower, location hurdles and other challenges in retention of skill-based talent create major challenges to maintain quality in the shop floor.
Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)
KRA1 Quality Assurance o Responsible for to deliver the good quality of product to customer.

• Ensure the inspection of Fabrication anodizing and powder coating products as per customer requirement.
• To assess the quality of the billets from time to time ensure right quality
• To develop a quality culture through continual improvement and team working analyses reason for NCRs and initiate monitor and implement corrective actions
• Ensure the guidelines are followed in the case of products where special testing is required to satisfy the customer liaison external agencies for the third-party inspection.
• Analyze customer complaint initiate monitor and implement corrective action to prevent the recurrence of complaints.
• Identify and train employees on any special needs identify for effective working of the system to develop the right competence.
• Ensure the timely completion of final inspection and clear material for dispatch
• CMM operation and program preparation.
• Welding testing and qualification process.
• Coordinating for Qualicoat audits.

KRA2 Customer audits (Supplier assessment audit) o Preparing the supplier assessment document, investigating with other department for required details to fill up the format.

• Recording the required reports, supporting documents at one place to support the audit.
• Review the audit points with reporting manager & closing the NC with supporting documents & maintain the records.

KRA3 Customer complaint and resolution process. o Preparing 8D report for customer complaint reviewing with team and share with customer for corrective action.

• Visit to customer to understand the complaint from customer. understand the application and take proper corrective action.
• To train internal team on the application of our products as per customer requirement.

KRA4 ISO 9001-2015 and IATF 16949-2016 System o Conduct internal audit as per the ISO 9001-2015 and IATF 16949-2016 System.

• Assisting in organizing external audit and certification as per the ISO 9001-2015 and IATF 16949-2016 System.
• Review the audit points with reporting manager & closing the NC with supporting documents & maintain the records.

KRA5 Process Control o Review and update of the PPAP documents.

• Conduct Product audit and layout inspection report as per plan.
• Reviewing the process parameter for the automotive parts.
• Validating the trail samples in fabrication.
• Conducting Statistical Process control analysis.
• Conducting Measuring system analysis.
• Supplier audits for Billets and outsourcing products.
• Gauges and measuring system implementation for various products developed.

Skills Required