AH Fabrication

Aditya Birla Group

Fresher

Kuppam, India

Posted 6 hours ago

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Job Description

Business	Metals
Unit	Downstream Kuppam Extrusion
Location	Kuppam
Poornata Position Number of the job		Reports to Poornata Position No :
Poornata Position Title of the job	AH Fabrication	Reports to Poornata Position Title :	SH Fabrication
Function	Manufacturing operations	Reports to Function :	Manufacturing operations
Department	Production	Reports to Department :	Production
Date of Last Updation/Approval

1) Job Purpose

Monitoring Fabrication department's production activities for meeting specifications and deadlines of internal & external customers by liaising with peer's departments and Fabrication Shift Supervisors.

2)Dimensions:

Business/SBU/Unit Revenue

403 crores.

Business Workforce Number

Unit Workforce Number

MS	LMS	Workmen	Contract	Total
80	261	2	336	679

Function Workforce Number

MS	LMS	Contract	Total
19	192	293	504

Department Workforce Number

MS	LMS	Contract	Total
3	36	152	191

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

Department	Budget (Cr)	Revenue (Cr)	Volume(T)	Major Customers	Annual Capacity(T)	Geography/Markets
Fabrication	9.3	18	2049	Titan, PT Hitachi, Aerocompact, Hero, Ecoppia, Corob	4800	Formworks, Solar, Automotive, Industrial 50% Export business

3) 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. Kuppam Fabrication adds Value on Extruded Aluminium profiles by performing processes like MIG welding, CNC Machining, Cutting, Punching, Forming, Printing, Threading & Assembly for Automotive, Formworks, Solar and Industrial segments. Kuppam Fabrication equipped with 8 Qualified welders, 3 & 4 Axis CNC Milling, Hydraulic and Mechanical Forming & Punching, External 4-start threading, Thermal drilling technologies and it can produce 300 to 400T per month with Rs. 520 NAV(net added value) per man hour. Job Challenges: Maintaining Productivity, Quality for delivering targeted KPI's due to change in crew due to wide fluctuations in orders which are project based and majority of workforce is off roll.

4) Key Result Areas/Accountabilities:
Key Result Areas/Accountabilities	Supporting Actions
Safety - To build a strong Safety culture in the plant with the objective to make this factory ZERO HARM and to provide a safe working environment to employees, contractors	Monitor, Review & update the fabrication processes regularly for safe & enviro-friendly operations. Attending safety trainings and cascading the learnings to downstream. Having frequent rounds in shop floor to identify & report Near misses and potential incidents together. Walk to shop floor, observe safety behaviors of employees, and communicate to them and upload with action plan in Enablon App. Machine guarding - List & Observe all equipment's of plant and ensure to have safeguarding to all equipment's along with core team
Focus on sustainability of fabrication dept	Drive improvement that light of highly illuminating sheet to be provided and all unwanted lights off in day light and machines are off when not in use and all are identified through line audit in each shift by supervisor/engineer There shouldn't be single point in air leakage and frequent change of compressed air pipes or alteration to aluminium pipes to avoid pipe damages/breakages Conducting 5s trainings and auditing 5s zones
Improve Profitability and Cash Flows	Improve NAV(net added value) per man hour by Avoiding Non-value added activities by monitoring production on daily basis and effective planning by co-ordination with PPIC & sales Monitor process rejections in fabrication processes on daily basis
Production Planning and maintaining documents	Preparing the daily plan based on available orders and machines with coordinating with sales and planning team Ensuring the raw materials, consumables, fasteners on time to the production Analysis of daily production and tracking & follow ups the same. Requesting to internal teams to clear for incoming orders, drawings, inspection reports and addition requirements based on customer feedback and needs Anticipate team work to finish the production on given time. Responsible for safety measures, process deviations and change in concurrent plan of production Discussion with all depts to clear on time internal process issues with die shop, extrusion, Anodizing, Powder coating, packing and dispatch etc Calculating takt & leading time for the processes and customers Preparing and analyzing the daily production data and KPI reports with appropriate targets to the line. Reviewing the OEE. Tracking and updating all the orders Records of fabrication processes
Indents making	Daily tracking and maintaining minimum stocks by Ordering the regular consumables and fasteners based on available orders and forecasts Getting quotes for new projects or existing process to reduce delivery times and savings to organization
Internal Audits	To Ensure all the documentations required for audit are in place related to safety, production, and quality Maintain all records, proofs and actions for refreshment trainings and closing NCs Internal IATF auditing other depts
Stock Inventory and accountability of Outsourcing (Servicing)	Verify consumables, aluminum profile, equipment, and job work stock Maintaining less than 30MT WIP Consolidating all inward and outward material Outsourcing which is not feasible or capable Preplanning & ensuring with on time material supply (Inward & Outward) Ensuring quality products are supplying and delivering back the same Record and closing of PO's on right time
Meetings and troubleshooting's	To review production plan execution with supervisor To review production challenges with boss for facilitating needs of urgency Ensure no deviation in flow of achieving production and delivery with internally related depts Assuring no bottleneck ness, increased productivity, Poka-yoke and contingency plan
Performance feedback	Feedback and Evaluation of performances of supervisors Valuation and finalization of peak performances of operators Setting up of new goals and challenges

5) Job Purpose of Direct Reports:
Position Title	Job Purpose	Position No.
Shift Supervisor	Achieving shift targets by monitoring shift production and Line inspection
Supervisor - SMS	Assembly & packing of SMS and Fabrication orders

6) Relationships:
Relationship Type (Internal or External)	Frequency & Nature
SH Fabrication	Daily - Seeking advice, consultation, and approvals.
AH Extrusion	Daily - Raw material requirements
AH Packing	Daily - Packing related services
AH Dispatch	Daily - Dispatch related services
AH PPIC	Daily - Planning activities
AH SCM	Daily - Procurement of consumables, outsourcing,
AH QA	Daily - Process audits, Customer related meetings
AH PD	Daily - New production development
AH Anodizing	Daily - Raw material requirements
AH Powder coating	Daily - Raw material requirements
AH Finance	Daily - For Indent creation
AH HSE	Daily - Safety
External Customer	Need basis - Customer complaints, technical meetings, new development
External Suppliers	Need basis - Procurements.

7) Organizational Relationships:
Position that It reports into	Position and its peers (Nop = )	Position/s that reports into (Nop = )
SH fabrication	AH PPIC AH Extrusion AH Die shop AH Anodizing AH Powder coating AH Packing AH Dispatch AH Store AH SCM AH Maintenance AH PD AH QA AH Projects AH HSE	Shift Supervisors Supervisor - SMS and Fab packing

Declaration: This job description is a true reflection of the position AH Fabrication
	Job Holder	Reports to Manager
Name
Date of Entry / Approval