Job Description

Business	Metals Corporate
Unit	Downstream Kuppam Extrusion
Location	Hindalco, Kuppam
Poornata Position Number of the job		Reports to Poornata Position No :
Poornata Position Title of the job	AH Mechanical Maintenance Value Add	Reports to Poornata Position Title :	DH Mechanical Maintenance
Function	Engg, Main & Utility Services	Reports to Function :	Engineering
Department	Engineering	Reports to Department :	Engineering
Date of Last Updation/Approval

1) Job Purpose

To plan, coordinate and carry out maintenance activities of Value add (Anodizing, Powder coating, Fabrication) equipment's, Material handling equipment, Post extrusion, ware house. To plan for continual improvement, redesigning systems and practices to maximize availability and enhance reliability of plant and equipment within budgeted cost. To execute all capital expenditure projects keeping the overall project cost and time within budget. To Coordinate WCM activities and Integrated Management System - ISO 9001,ISO-14001 and OHSAS-18001 of the Mechanical maintenance department for the overall manufacturing excellence . To Plan and implement effective spare parts management system in coordination with supply chain department

2)Dimensions:

Business/SBU/Unit Revenue

403 Cr

Business Workforce Number

Unit Workforce Number

MS	LMS	Workmen	Contract	Total
80	261	2	336	679

Function Workforce Number

MS	LMS	Contract	Total
19	26	7	52

Department Workforce Number

MS	LMS	Contract	Total
3	13	0	16

Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter

3) Job Context & Major Challenges:
Job Context: The global Aluminium 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. 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 design, challenging operations, involve highly skilled technicians, special machinery and processes. This unit has two 8-inch press with a capacity of 16KT per annum, anodizing 2.5 KT per annum, powder coating 3.2KT per annum along with various fabrication machinery like manual and robotic welding, CNC cutting & machining centers, Flaring & collaring, assembly lines serving for Building & construction (38%) , industrial (41%), Exports (11%), Automotive (7%), and solar segments (3%). This 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, setting up new fabrication facility, additional anodizing tanks and a brand-new extrusion press. To maintain the health of old equipment's by timely, planned and systematic maintenance. Ensure the availability and reliability of equipment within the P&B target. Enhance health and reliability of equipment by suitable technical / design modifications Study and train the staff and operatives on the complex hydraulic system of the Anodizing , powder coating and various fabrication machines to independently manage breakdowns in shifts Conceive, acquire and assimilate new technologies in the area of engineering and maintenance Consistent cost reduction initiatives on all fronts viz. maintenance cost, power consumption (resource conservation) ,import substitution etc and identifying new areas for cost reduction to sustain cost competitiveness To support production centers in minimizing small stops and to improve productivity Minimize turn-around time for the shutdown maintenance of Control the inventory of Mechanical maintenance stores under optimum level to bring down inventory carrying cost. Vendor development for cost competitiveness and import substitution Motivate people to participate actively in WCM activities. Check and approve design and drawings of spares and new construction.To train the maintenance crew Job Challenges: Enhancing skill of workmen and proficiencies of maintenance team members. Manpower retention and hiring - Due to location constraint Spare parts management due to lack of ERP system

4) Key Result Areas/Accountabilities:
Key Result Areas/Accountabilities	Supporting Actions
Plan, co-ordinate and implement maintenance activities to maximize availability of plant / equipment / machineries at minimal cost.	Criticality ranking of all equipment and machineries. Classify critical & non-critical equipment Maintenance decision-making by fixing suitable maintenance strategies / frequencies based on relevant data. Preparation of preventive maintenance master schedule for equipment & machinery. Facilitate Computerized Maintenance Management System for Planned/Predictive/Corrective and Breakdown Maintenance. Ensure execution of maintenance without slippage to maximize availability. Ensure maintenance of equipment history (system based) for all major /critical equipment. Analysis of breakdowns followed by corrective and preventive actions Technical / Design modifications to improve the level of reliability and availability of plant and equipment. Ensure Condition Monitoring of critical equipment. Spare parts management Calculation and dissemination of Maintenance Performance Indices Maintain the plant and within planned breakdown (Avg./month)
R & M Cost	Assist DH in preparation of budget and ensure spending within approved plan Develop vendor for better service at reduced cost. Analyze variations and take corrective steps to ensure R&M cost within budget Vendor development for cost effective spares and for import substitution. Effectively Negotiate with vendors for better cost advantage and achieving the organizational target
Spare parts management	Spares management with the help of supply chain department Develop new vendors. Identify spares for new equipment. Review bin items and take corrective actions. Import substitution
Statutory requirements	Ensure Mechanical system meets all statutory requirements as envisaged in factories act and rules. All lifting tackles are maintained as per Legal metrology rules/acts.
Product Quality	To ensure the calibration of all the mechanical related gauges and instruments. Maintain all heat treatmentfurnaces and ensure proper operation to ensure product quality. Ensure operation of all equipment at the desired operation parameters
Projects / Developmental Activities	Carry out process developments for production increase and reduction in raw material / energy consumption. Preparation of RFA s as per approved Capex plan Freeze the technical specification of the equipments Vendor hunting Supplier/ Vendor visits Planning, procuring, erection and commissioning of Capex projects.Implementation and monitoring of Environment related aspects related with projects Ensure the work permit system Ensure the contract workers safety especially working at heights for Medical check up. Ensure the safety practices in materials handling, availability and usage of PPE s for work Implement the recommendations of the technical audits carried out by any third party
IMS System Upkeep	To maintain all the documents/ records of IMS for mechanical maintenance department. To amend necessary changes in documents, procedure and others if required. Conduct regular audits Close and take corrective action for all the NCR s during external or internal audits
SAFETY	Periodical assessment Potential Risk and implementation of risk mitigation plans as per Corporate Guidelines Ensure statutory testing and certification of lifting equipment and lifting tackles, pressure vessels etc as per plan. Building stability evaluation and certification Ultrasonic examination of lifting tackles / crane hooks Ensure Legal and statutory compliance as applicable as per Corporate Guidelines Implement the decisions of EOH & S committee and other safety committees. Work towards achieving zero accident frequency rate and zero severity rate. Conduct SAE (Safe Attitude Encouragement) rounds to monitor and eliminate unsafe acts and conditions to ensure zero accidents, zero incidents and zero injuries Ensure 100 % compliance to safety guidelines and other statutory requirements. Conduct JSA and share results across the units. Monitor and eliminate the unsafe acts and conditions for zero accidents and incidents in the Dept

5) Job Purpose of Direct Reports:
Position Title	Job Purpose	Position No.
AH Extrusion

6) Relationships:

Relationship Type

(Internal or External)

Frequency & Nature

FH Engineering

For getting the feedback on performance of the equipment and getting the equipment for maintenance (Daily)

For appraising the status of maintenance and project activities RFA approval clarifications, Interaction on IMS, WCM activities, Capex Projects overall status reporting, Monthly Works report submission (Monthly/Weekly/Daily as applicable)

Head: Mechanical

For appraising the status of maintenance, discussion, Resource Requirements, Project status Updating & its Review (Daily)

Head:Projects&Materials /Finance

Project discussion, (As and when required)

Maintenance team

For appraising the status of maintenance & project activities (Daily)

SCM team

For material follow up and procurement

7) Organizational Relationships:
Position that It reports into	Position and its peers (Nop = )	Position/s that reports into (Nop = )
FH Engineering	SH Mechanical - Extrusion SH Electrical - Plant SH Electrical - Power & Utility DH Production SH Safety SH Value add DH Die shop SH Quality Assurance SH Finance & Accounts SH packing SH Dispatch SH SCM DH HR DH Planning SH IT SH Projects	AH Mechanical Maintenance

Declaration: This job description is a true reflection of the position - SH Mechanical Value Add
	Job Holder	Reports to Manager
Name
Date of Entry / Approval

AH Mechanical Maintenance