SH Process / QA - Cast House

Business
Metals
Unit
Hindalco, Downstream Aluminium Extrusion
Location
Kuppam, Andhra Pradesh
Poornata Position Number of the job
Reports To Poornata Position No
Poornata Position Title of the job
SH- Process & QA
Reports To Poornata Position Title
Head Cast House
Function
Project
Reports To Function
Project
Department
Cast House- Project
Reports To Department
Project
Date of Last Updation/Approval
Job Purpose
To enable Cast House Plant to achieve full business potential by driving operational excellence, process efficiency, and product quality in upcoming Cast House dedicated to producing high-precision and aesthetic extrusion sections feedstock billets.
The role will focus on developing and implementing robust process control systems, optimizing production workflows, and ensuring adherence to global quality standards.
Dimensions:
The project involves the participation of multiple technology suppliers, OEMs, EPC contractors, consultants, construction agencies, and service providers working simultaneously across various work fronts within the project site. Effective coordination and interface management among all stakeholders will be critical to achieving project objectives.
Considering the aggressive project schedule, construction, installation, testing, and commissioning activities will be executed on a 24x7 basis across all three shifts, requiring robust planning, resource management, safety oversight, and continuous monitoring of project progress.
As the project is being developed from the ground up, all essential project infrastructure and support facilities will need to be established, including temporary power supply, construction utilities, site offices, storage facilities, workshops, contractor amenities, communication networks, and logistics arrangements.
Business/SBU/Unit Revenue
Business Workforce Number
Unit Workforce Number
Function Workforce Number
Department Workforce Number
Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter
Process and Quality systems need to be stabilized in sync with committed ramp up plan and ensuring consistent, continuous and sustainable improvement in 22KTPA Cast House.
Job Context & Major Challenges:
Job Context
Hindalco is establishing a new state-of-the-art Aluminium Extrusion facility at Kuppam, Chittoor District, Andhra Pradesh, to manufacture specialized aluminium extrusion products catering to high-growth sectors such as electronics, automotive, industrial machinery, and consumer durables. The proposed extrusion plant will have an installed production capacity of 7.5 KTPA.
To support the billet requirements of the extrusion facility, a new Cast House Plant is being developed within the same campus. The Cast House will produce high-quality, specialized aluminium extrusion billets with a planned capacity of 22 KTPA, ensuring a reliable and integrated supply chain for downstream extrusion operations.
The Kuppam facility is being developed as a strategic manufacturing hub for value-added aluminium alloy extrusion products, strengthening Hindalco's presence in key domestic and international markets while enhancing operational efficiency through integrated Cast House and Extrusion operations.
Key Plant Facilities and Equipment
The project includes installation, commissioning, and integration of advanced process equipment and supporting utility systems, including:
Cast House
Induction Melting Furnaces
Electric Holding Furnaces
Electric Homogenizing Furnaces
Cooling Chambers
Billet Casting Machine
Degasser System
Porus Tube Filtration (PTF) System
Ceramic Foam Filtration (CFF) System
Billet Handling and Sawing Machines.
Extrusion Plant
9" Aluminium Extrusion Press
Ageing Ovens
Fabrication and Cutting Machines
Electrolytic Degreasing System
Material Handling Systems
Utilities & Infrastructure
Electrical Distribution Systems
Instrumentation, Control and Automation Systems
Compressed Air Systems
Cooling Water Systems
Fire Protection Systems
Utility Networks and Auxiliary Facilities
Plant-wide Material Handling and Logistics Systems
Job Challenges
The new proposed Cast House & Extrusion Complex is a brownfield expansion of the exiting installation. This Facility is coming up at the adjacent land parcel which poses all the dynamic challenges like that of Greenfield expansion.
There is no basic infrastructure available at the site. The necessary infrastructure needs to be conceived and erected for ensuring smooth Erection of the equipment.
This role is responsible for driving Cast House quality excellence by closely engaging with customers to understand their requirements and translating them into robust production and quality control practices. The role provides technical guidance to operations teams in problem-solving, process optimization, and quality parameter control to achieve optimum output, zero-defect manufacturing, and superior customer satisfaction. It involves monitoring and analysing process performance, conducting inspections of inputs and outputs, identifying improvement opportunities, and implementing corrective and preventive actions across Cast House at Kuppam.
A critical responsibility of the role is to ensure the highest standards of product quality through accurate measurement and control of key quality parameters such as Chemistry, Metallurgical parameters, Hydrogen (H?) levels, Inclusion Levels, thereby minimizing substandard extrusion billet generation and ensuring consistent compliance with customer specifications.
The role also plays a vital part in maintaining safety, health, and hygiene standards during casting operations, ensuring adherence to approved furnace alloying practices, maximizing first-pass yield, and achieving excellence in Layer Process Audits (LPA).
As the primary interface for customer quality management, the position requires regular customer interactions, site visits, material defect assessments, and proactive engagement with operations teams to ensure timely closure of customer complaints and CAPA (Corrective and Preventive Actions), thereby enhancing customer confidence and meeting Service Level Agreement (SLA) commitments.
Lead day-to-day process & quality assurance activities at the project site, ensuring adherence to safety, quality, cost, and schedule requirements.
Ensure all activities are executed in accordance with approved drawings, technical specifications, engineering standards, and project schedules.
Coordinate closely with Civil, Mechanical, Electrical, Automation, Utilities, Process, and Commissioning teams to ensure seamless project execution and timely resolution of interface issues.
Monitor construction progress, identify execution bottlenecks, implement corrective actions, and ensure compliance with project milestones.
Supervise Installation and alignment of Cast House Equipment.
Support the utilities team in the installation, calibration, testing, and commissioning of systems associated with Cast House Balance of Plant (BOP) facilities.
Prepare daily and weekly execution plans, allocate manpower and resources, monitor contractor productivity, ensure material readiness, review work permits and method statements, and promptly resolve site technical issues.
Lead and coordinate pre-commissioning and commissioning activities with OEMs and contractors to ssupport integrated plant startup and stabilization.
Coordinate with OEMs, EPC contractors, consultants, and project stakeholders to review progress, verify work quality, approve measurement sheets, ensure contractor compliance with safety standards, and resolve technical and commercial issues.
Maintain close engagement with the Procurement Team to ensure timely availability of materials, expedite critical procurements, monitor delivery schedules, and support effective project execution in line with project priorities and milestones.
Ensure compliance with applicable safety standards, quality requirements, statutory regulations, and project governance processes throughout the project execution lifecycle.
Absorbing new technologies, stabilizing processes, and fine-tuning operating parameters while simultaneously increasing production volumes.
Managing stringent product qualification requirements for specialized products.
Developing process capability with a relatively inexperienced workforce and addressing skill gaps in process control.
Identifying and correcting design deficiencies while enhancing reliability, productivity, and operational performance beyond design capacity.
Managing high production volumes while maintaining stringent quality control standards and zero-defect expectations.
Responding to dynamic market requirements and increasingly stringent customer specifications in a highly competitive environment.
Preparing and sustaining Cast House compliance with ISO 17025, ISO 9001, I

Work arrangement
No