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Aditya Birla Group

Sambalpur, India

2-4 Years

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Posted 12 hours ago
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Job Description

The purpose is to operate, monitor, and maintain the circle blanking line to ensure accurate and efficient production of circular metal blanks from coils or sheets while maintaining high standards of quality, safety, productivity, and equipment reliability. The role combines precision process control with hands-on preventive and corrective maintenance responsibilities to ensure smooth and uninterrupted manufacturing operations.

The staff is responsible for setting up and running the circle blanking line, including coil feeding, leveling, press or punching operations, scrap removal, and stacking of finished blanks.

The individual ensures that each circular blank meets specified diameter tolerances, thickness consistency, flatness requirements, and edge quality standards with minimal burr formation. Proper die alignment, feed accuracy, and press settings must be maintained to prevent defects such as ovality, surface scratches, dents, or dimensional variation.

In addition to operating the line, the role includes conducting routine inspections, lubrication, cleaning, die checks, and monitoring of mechanical, hydraulic, and pneumatic systems. The operator identifies early signs of tool wear, misalignment, abnormal vibration, or mechanical faults and performs minor repairs while coordinating with the maintenance team for major breakdowns. This proactive approach helps minimize downtime and improve equipment lifespan.

The position also contributes to material yield optimization by reducing scrap generation and ensuring proper nesting and feeding accuracy. Strict adherence to safety procedures is essential due to high-speed press operations, moving coils, and scrap handling systems. The individual maintains production records, supports quality checks, and coordinates with planning and quality departments to ensure timely delivery of defect-free circular blanks.

3) Job Context & Major Challenges:
Job Context: FRP- Phase 2 is for enhancing the Aluminium Flat Rolled Product capacity of Hindalco by additional 340 KTPA over 135 KTPA (Existing Hirakud FRP) to a total of 475 KTPA to cater to the growing requirement of high-quality products like Can Body Stock, Industrial Products, and Electronics in Asia, MENA, and East European Regions, in addition to meeting the domestic requirement. From the conception, this project is expected to have a second phase to fully utilize the inherent capacity of the hot mill, there by optimizing the productivity and resources to have the unique lowest cost position in the world FRP market. Second Phase envisages commissioning in two phases of Phase 2A & Phase 2B with a total of two cold mills (One each in 2A & 2B) with all finishing facilities like, Tension levellers, Degreasing lines, Slitting Lines, Cut-to-length, Annealing furnaces, Roll grinding machines, Packing lines and Remelt furnaces with cast houses, making it a complete new Aluminium cold rolling mill complex. The hot rolled coils will be produced in the existing Hirakud FRP hot mill and will betransported to the new cold mill complex as an input material. In order to increase the Hot Mill capacity, One additional finishing mill stand, One new coiler and coil conveying system, 3 pusher type furnaces for slab heating and Edger at Roughing mill at the Hot Mill will be added. The finishing lines process coils to achieve specifications such as customer specified width and weight of coil. They are also required to ensure that the surface defects along with gauge variations from upstream processes like Hot Mill and Cold Mill are detected, so that customer is not affected. Along with detection of upstream defects, finishing line also required to ensure that defects are not generated in finishing lines. Finishing line equipment are the widest and biggest in terms of production and specifications amongst downstream units of Hindalco. Danieli Slitter has the capability to process coils of gauge ranging from 0.1mm to 1.5mm of coil weight upto 20MT. Danieli Slitter is the only slitting unit in India with Post Lub facility to process Can Body Stock Coils. It has CNC operated Center slitting unit. Cut To Length is also the widest sheet making line of Hindalco with processing capability of 6000mm/2100mm size capability. Cut To Length has one of its kind 6-High Sheet Leveling Unit along with one-of-its-kind automated vacuum stacker , cushion stacker for narrow and shirt length sheet stacking and CNC operated trimmer unit to process coil gauge ranging from 0.1mm to 1 mm. Apart from that there , Tension Leveler cum degreasing line which is having unique capability to process tension leveled aluminum coils with a degreased wash with Alkali and Acid medium. The coil gauge ranges from 0.1mm to 1mm and process width ranges from 700mm to 2100mm. Also there is multi slitting line that caters slit products least narrow is 40 mm while the thickness ranges from 0.3mm to 3mm along with an integrated slit packaging line. Moreover there is a circle blanking line that can produce blanks from diameter ranging from 170 to 650 mm and thickness ranging from 0.5mm to 6.5mm along with a disc packaging line. The finishing lines are attached to Coil Packing Line and Sheet Packing Lines are latest equipment with automatic packing operations. This role is responsible for operating, controlling, and maintaining the circle blanking line to ensure precise and efficient production of circular metal blanks from coils or sheets while maintaining high standards of quality, safety, productivity, and equipment reliability. The role involves setting up decoiling, feeding, leveling, and blanking press operations adjusting die alignment and press parameters to achieve accurate diameter, roundness, flatness, and minimal burr formation and ensuring proper stacking to prevent surface damage. In addition to production responsibilities, the individual performs routine inspections, lubrication, die checks, minor repairs, and troubleshooting of mechanical, hydraulic, and pneumatic systems to minimize downtime and extend equipment life. The position also focuses on scrap reduction, material yield optimization, safety compliance, and coordination with quality and planning teams to ensure timely delivery of defect-free circular blanks for downstream forming processes. Finishing Line has the main interface with theexternal customers and final authority to qualify the material for going to the customer and ensuring they are of world class standards. Hence, understanding of customers requirements is an important aspect of the role. This role is also responsible for monitoring maintenance of health, safety environment norms and statutory compliance with focus on maintaining pollution control norms for re-oiling and lubrication of cutters as well as packing materials. Imparting relevant training to the material handling operators to enforce compliance and prevent injury. Job Challenges: Achieving precise diameter tolerances, roundness, and flatness of circular blanks is a major challenge. Variations in coil thickness, material grade, or strip tension can affect blank accuracy. Maintaining consistent press settings and feed alignment requires continuous monitoring and technical expertise. Excessive burrs can cause rejection in downstream forming processes such as deep drawing or stamping. Maintaining correct die alignment, punch sharpness, and press parameters under varying production loads is demanding. Blanking dies and punches are subject to wear due to repetitive high-pressure operations. Tool wear can result in burr formation, edge deformation, or dimensional variation. Monitoring tool condition, maintaining proper clearance, and ensuring timely regrinding or replacement is critical but challenging during continuous production. Preventing scratches, dents, oil contamination, and handling damage during feeding and stacking is essential to avoid downstream rejection. Mechanical issues such as bearing failure, shaft misalignment, hydraulic leaks, or tension control malfunction can cause unexpected downtime. The staff must quickly diagnose and perform minor repairs while coordinating major repairs efficiently. Risk of cuts, entanglement, and crush injuries is high if safety procedures are not strictly followed. Reducing changeover time without compromising accuracy is challenging. Balancing production targets with preventive maintenance duties can be demanding, especially during tight production schedules.
4) Key Result Areas/Accountabilities:
Key Result Areas/Accountabilities	Supporting Actions
Business Excellence	Machine uptime by reducing breakdown frequency. Reduced changeover time through better knife presetting and planning. Increased line efficiency (OEE improvement initiatives). To achieve daily/monthly production targets consistently. Preventive maintenance checklists. Identify early warning signs of bearing failure, misalignment, or vibration. To reduce unplanned downtime through proactive troubleshooting.
Cost	Scrap & Yield Improvement by minimizing scrap generation Maintenance Cost Control by proper handling and maintenance of spare parts and consumables. Downtime Reduction by improving machine availability , TAT and reducing setup time.
Cash	Working Capital Improvement by reducing WIP - minimize rework. Inventory upkeep by ensuring proper labeling and traceability to avoid dispatch errors Scrap Value Optimization by reducing unnecessary scrap generation.
Customer	Supervising packaging to match customer expectations in terms of volumes, specification and quality Minimizingresponse time in providing information and solutions to all internal and external customers
Sustainability & Compliance	Implementing compliance of all statutory and environmental norms with focus on environmental guidelines and manpower deployment Driving WCM, Kaizen and improvement projects for continuous improvement and greater sustainability Monitoring good housekeeping practices and green initiatives in area under jurisdiction
Safety	Monitoring implementation of safety norms with respect to line operations Monitoring implementation of HIRA, JSA, LOTOTO and work permit systems Facilitating safety related training to own and contractual teams to embed a safety culture as per standardsand achieving zero incident Implementing emergency handling readiness through continuous review and course correction
People development and engagement	Monitoring intake and deployment of appropriately trained contractual workforce in area under jurisdiction and ensuring their continuous training and wellbeing as per company guidelines. Facilitatingcompetency building and multiskillingthrough training initiatives to enhance technical and behavioral competencies towards greater productivity.

5) Role Specific Competencies
Technical competencies	B Tech in Mechanical/Electrical/ECE/Metallurgy/Production with about 2 years of experience Understanding ofSlitting Process ,Knife Setup & Alignment ,Levelling Expertise ,Machine Operation Skills ,Quality Inspection & Measurement ,Preventive & Basic Maintenance Skills ,Safety & Risk Awareness ,Basic Knowledge of TPM & 5S.