SH Process /QA - Extrusion

Business
Metals
Unit
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 Extrusion
Function
Extrusion
Reports To Function
Quality
Department
Quality
Reports To Department
Quality
Date of Last Updation/Approval
New / --------------
Job Purpose
To enable Kuppam Extrusion Plant to achieve Full Business Potential by driving operational excellence, process efficiency, and product quality in upcoming Aluminium Extrusion dedicated to producing high-precision Electronics, Automobile and Machining component. The role will focus on developing and implementing robust process control systems, optimizing production workflows, and ensuring adherence to global quality standards. This is to be achieved by --
Development of knowledge and expertise
Develop in-depth knowledge of Aluminium Extrusion manufacturing processes, including Billet preparation, Extrusion, Quenching, Stretching, Ageing, Die & Tooling.
Stay updated with advancements in Extrusion Technology for Electronic, EV/Automotive & machine component manufacturing and ensuring the adoption of best practices and innovations.
Build expertise in process optimization tools, quality control systems, and data analytics for continuous performance improvement.
Foster collaboration with global technical partners, OEMs, and research institutions to enhance process capabilities.
Mentor and develop team members, ensuring skill enhancement and knowledge transfer for sustained operational excellence.
Ensure compliance with internationally recognized quality management systems such as ISO 9001, ISO 14001, ISO 45000, BIS, IATF etc.
Develop expertise in automotive quality systems, including IATF 16949, to meet industry-specific requirements and customer expectations.
Build proficiency in statistical process control (SPC) and advanced quality tools for process optimization and defect reduction.
Implement robust quality assurance and quality control processes to ensure consistent product performance and reliability
Ensure reliable processes & effective problem-solving.
Establish & drive state-of-the-art Extrusion Press Line equipment, Ageing and Extrusion processes.
Identify improvement needs, develop master plans to implement improvements at the Extrusion, Quenching, Stretching and Ageing Process.
Guide and lead root cause analysis to solve processing and quality issues, ensure monitoring of the effectiveness of corrective actions, and strengthen problem-solving skills at all levels of the organization.
Improve horizontal replication of best Extrusion line instrumentation, installations, and practices across Extrusion line equipment.
Dimensions: Ensuring 100% compliance with customer specifications and international quality certifications. Optimizing manufacturing costs, ensuring budget adherence, and driving cost-saving initiatives. Collaborating with internal stakeholders and external stakeholders.
Unit Revenue
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
Equipment needs to be installed in the given time lines, as these involve automation, instrumentation engineer plays a critical role to operative and Plant Operation producing 7.5 KT.
Job Context & Major Challenges:
Job Context
The Indian aluminum Extrsuion industry is rapidly evolving, driven by increasing demand for high-quality Electronic, EV segment, Automobile and Machining components manufacturing. The new plant represents a strategic investment aimed at capturing emerging market opportunities and strengthening the Hindalco position in Extrusion market. The role operates in a dynamic environment requiring seamless integration of cutting-edge technologies, stringent quality requirements, and sustainable manufacturing practices.
The position will be at the forefront of commissioning, stabilizing, and scaling up operations at the new plant. This includes ensuring operational readiness, qualifying products to meet customer standards, and building a skilled workforce capable of managing advanced Extrusion manufacturing technologies. The role demands alignment with Hindalco's downstream corporate goals, close coordination with global partners, and an unwavering focus on safety, quality, and efficiency.
Key Challenges
Stabilizing new manufacturing processes and achieving consistent product quality during the commissioning phase.
Meeting stringent technical requirements for Extrusion products across diverse customer specifications specifically electronic and EV/Automobile segments.
Ensuring compliance with international quality and safety standards
Improve quality awareness, process discipline and rigor in process execution
Developing and maintaining strong relationships with key customers, certification bodies, and stakeholders.
Key Result Areas/Accountabilities:
Extrusion line Performances, Quality KPIs, RCA, Analytics,
Ensure consistent and optimized Extrusion production performance, focusing on recovery, process efficiency, and equipment uptime.
Drive adherence to quality KPIs, including internal/external rejection, customer complaint resolution, and product qualification success rates.
Implement robust RCA methodologies to identify, analyze, and eliminate recurring process and quality issues.
Develop and enforce standard operating procedures (SOPs)/Standard work Instruction (SWIs) for key manufacturing processes.
Key Result Areas
Supporting Actions
Extrusion line Performance
Optimize Extrusion Process recovery, process efficiency, and equipment uptime through process controls.
Quality KPIs
Monitor and improve rejection rates, ensure customer complaint resolution, and audits.
Root Cause Analysis
Conduct RCA for recurring issues and implement corrective actions for process gaps.
Analytics
Use data-driven insights for process optimization, predictive maintenance, and KPIs.
Digitalization
Drive adoption of IoT tools, smart manufacturing systems, and real-time monitoring.
Process Standardization
Develop and enforce SOPs for all critical manufacturing processes.
Customer Satisfaction
Ensure on-time delivery, product compliance, and consistent communication with clients.
Continuous Improvement
Lead CI projects for productivity, waste reduction, and operational excellence.
Compliance
Ensure adherence to ISO, IATF standards, and environmental and safety regulations.
Job Purpose of Direct Reports: NIL (NA) none
Position Title
Job Purpose
Position No.
NA
Relationship Type
(Internal or External)
Internal
Frequency
Nature
Cluster Head(s), Unit Heads
Regular
Productivity, Processes and Quality
Plant Engineering Team,
Regular
For deep dive into Extrusion line/Ageing issues, analysis, PM Optimization, FMEA, quality, Review processes on RCA/CAPA of the plant.
Central Quality
Regular
Processes and Quality issues
Unit Extrusion Teams
Regular
Implementation of best practices, identification of gaps, quality issues
HIC
Regular
Ideation and initiation of projects and investigations to improve Extrusion processes, RCA input, analysis of quality issues
HTU (Hindalco Technical University)
Regular
Understanding gaps in critical technical training requirement for each plant and bridging the gap in close coordination with HTU
HR / Purchase / commercial
Need based
For HR / Purchase / commercial related works
External
Frequency
Nature
Equipment Vendors
Regular
Discuss & validate the proposed technological upgrade/ changes and other design issues arising as an outcome of MOC process
Service Vendors
Regular
Facilitate the Resource mobilization process both in terms of quality and cost for needed support by plant as a response to failures / issues
Customer
Regular
Production specification, CSR, New Product development, Plant qualification, Customer complaints and Joint development projects
Organizational Relationships:
Position that It reports into
Position and its peers (Nop = )
Position/s that reports into (Nop = )
Head Extrusion
SH Electrical & Automation engineer (3)
SH Mechanical engineer (3)
SH Process & QA (2)
NA

Work arrangement
No