Job Description

:Hindalco has decided to enter in to Copper Alloy rod manufacturing. The site is a brownfield site with plant and machinery already installed. However, the peripheral setup is yet to be done to commence the operations. Said role is expected to take up the Operations & Maintenance Head role to commence the trails and then commercial ramp up of the plant operations.This role is crucial in addressing the complexities of manufacturing copper alloys and ensuring that we have the skilled workforce and precision in production necessary to meet the market's requirements.As the market's requirements are very dynamic (basically due to energy efficiency and sustainability), manufacturing copper alloy product has its own complexities.As this is a B2B product, considering the downstream application at the customer's works, we must maintain quality and uniformity of alloy mixing during the process.Whenever we want to cater to a new customer, we must undergo a rigorous approval process. This process, which can take a few weeks to more than three months, is crucial as it ensures that our products meet the highest standards and are tailored to the specific needs of each customer.Major Job Challenges:Production Optimization: address the challenges and obstacles in producing high quality product to achieve efficiency and minimise the time and wastage and increase the effectiveness of overall system.Reduction in Defects: Maintain high quality of product as per the HIL standards, identify defects in the quality and aim to reduce them in manufacturing process.Daily Maintenance: Keeping the Machinery in optimal condition by executing Maintenance.Inventory Control: Monitoring the production as per the demand forecast to avoid both excess and shortage and meet customer satisfaction and delivery deadlines, including Waste Management and energy conservation.Regulatory Standards: Comply to all industry regulations and compliances to mitigate all hazardous and non hazardous materials, risk assessment and mitigation for overall production and other requirements.4) Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)Key Result AreasSupporting ActionsSafety & Workplace Management

• Drive strategic / area wise improvement initiatives under the guidance of AET/PBU Head and ensure all statutory requirements in the Area are met with focus on air, soil and water pollution control, for hazardous wastes and effluents.
• Follow procedures & plans, for compliance with statutory, regulatory & environmental norms and HIL standards for Occupational Health, safety & environment.
• Eradicate the health hazards that arise out of occupational, design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
• Align with Kaizen and other improvement initiatives for greater sustainability of operations.
• Maintain workplace in order with respect to all Sub-areas (Level of 5-S).
• Follow safety standards & procedures (work permit system, JSA, SOP, SMP, TPM, O-TPM, storage and handling of hazardous material, etc.) for accident prevention in the Area.
• Follow LOTOTO (Look-Out, Tag-Out & Try-Out) guidelines for personnel safety.

Daily Work Management

• Comply flawless daily work by undertaking following:
• Execution of DMTs excellence standards across the Area
• Achievement of monthly, quarterly and annual P&B targets of the assigned Area in terms of quantity & quality
• Abide of Daily Performance Indicators (DPIs) within the team.

• Follow and adhere the clearly defined KPIV & KPOV (Key Performance Input / Output Variables) to DMTs with all the related production.
• Undertake 'Abnormality Correction' in DMTs through Root Cause Analysis and address unfavorable deviations through countermeasures (Kaizen, SPL, Visual Controls, Mistake proofing, Change in SWI, etc.)
• Align work priorities, execute plans on day-to-day basis pertaining to SQCDPM.
• Undertake daily & periodic 'Job Planning' through ERP system (EKAYAAN) for efficient daily workflow.
• Align with Model areas / machines devoid of unwanted items and make abnormality Identification (8 types) & redressal as a continuous process in all DMTs (5S & Kaizen).
• Execution of daily Operations, Production & Maintenance and take related decisions within the allocated budget.

Continuous Improvement

• Ensure continuous improvements using problem solving tools (RCA, OPL, Kaizen etc.)
• Drive FI, PI, Just Do It, Value Creation, and other improvement initiatives to improve productivity & cost efficiency of the Area.
• Create value through waste elimination, optimum resource utilization, productivity enhancement, etc.
• Eliminate inefficiencies and NVAs in the system for streamlining.

Asset Care & Equipment Reliability

• Undertake and eliminate the Root Cause of breakdowns, to minimize process disturbance and production delays.
• Ensure equipment availability & health in the area by following measures: plan & implement preventive maintenance, execute reliability testing & predictive maintenance, execution of shutdown & overhaul, and ensure timely breakdown maintenance with support from AET, if required.
• Achieve zero production loss due to equipment related breakdowns by following measures:
• Ensure availability of routine spares
• Use ERP System (EKAYAAN) and ensure complete adherence with maintenance schedule.

• Execute the implemented of best maintenance practices across the PBU and monitor its effectiveness in coordination with AET and CoE-Asset care, to attain higher uptime of Plant and equipment.
• Control overall cost of maintenance by following measures: track spare consumption by conducting regular reviews, control spare inventory at optimum levels at Shop floor.
• Ensure effective utilization & control of manpower and store expenses through recycling spares and waste reduction.
• Use ERP to maintain & monitor following and assist daily asset care:
• Calibration / overhauling & breakdown / corrective maintenance, data related to 'Critical Process Instruments'
• Execution of 'Work Order Cycle' to different agencies / departments by daily logbook keeping, recording maintenance record, etc.
• Structured data / check sheet for equipment details, job plan, safety plan, etc.
• Data related to maintenance history, jobs undertaken, and details of spares & consumables utilized.

• Observe and execute in the area of opportunity & execute projects for OEE improvement, technology upgradation, low-cost automation, maintenance cost optimization, digitalization (FI / PI / JDI), etc. to create maximum value for the PBU.
• Monitor the progress on condition appraisal for all equipment, sub equipment and assemblies and ensure that condition appraisal & refurbishing of equipment is happening as per the plan.
• Undertake continuous recording of special events, trip analysis, failure analysis, efficiency improvement, benchmarking, efficiency evaluation, etc. for scope of improvement.

Process Care & Quality

• Implement the culture of structured problem solving by ensuring implementation of FI, Just Do It, and any other project which is derived from chronic issues.

Customer Centricity

• Meet and exceed internal customer expectations, adhere with service level agreements (SLAs, Blueprints), and implement action, customer feedback & surveys.

Capability Building & People Engagement

• Develop Skillset of self and team members and maintain optimum Skill inventory.

Aditya Birla Group