AH Mechanical Maintenance

Hindalco Industries; Chittoor; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Hindalco Industries Limited, Kuppam plant in Andhra Pradesh, seeks a senior Maintenance lead to optimise extrusion presses, die shop machinery, and related facilities. You will drive preventive and predictive maintenance, manage multi-skilled teams, and align with safety and environmental standards.

Responsible for planning, budget reporting, and implementing continuous improvement to enhance equipment uptime and production efficiency across the site.

Responsibilities

• Lead the site Maintenance function for 2500 UST, 2200 MT hydraulic presses, and die manufacturing and correction machinery installed in 2008 & 2013 at Kuppam facilities.
• Plan and execute preventive and predictive maintenance of extrusion presses and die shop machinery to maximize efficiency and output.
• Develop and implement maintenance strategies, PM schedules, and KPI-driven improvements to reduce downtime and improve overall equipment effectiveness (OEE).
• Coach and develop maintenance teams, manage budgets and resources, and ensure safety, health, and environmental standards are followed.

Job description

Job Description

1) Job Purpose

Responsible for ensuring that both extrusion presses used to produce new and existing products run to their maximum efficiency and output. This includes planning and executing total preventive and predictive maintenance of both presses, die shop machineries. To maintain mechanical and hydraulics breakdown within target. This requires people management and budgetary / cost reporting.

2) Dimensions

Business/SBU/Unit Revenue403 crores.Business Workforce Number Unit Workforce Number
MSLMSWorkmenContractTotal802612336679Function Workforce Number
MSLMSContractTotal1926752Department Workforce Number
MSLMSContractTotal313016Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameterBP - Breakdown Target for the Year 2.8%
3 CAPEX Projects - 1.91Cr.

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.
Lead the site Maintenance function for 2500 UST, 2200 MT of Hydraulic presses, and die manufacturing and correction machineries which is installed in 2008 & 2013 at Kuppam facilities. Providing both a reactive and proactive, multi-skilled maintenance service on all operational equipment and facilities infrastructure. Responsible for planned scheduling creation and overseeing the adherence and timely completion of work carried out. Increase the site operational effectiveness, improve on project delivery, mean time between failure and downtime reduction, and manage and implement improvement plans, driving Key Performance Indicators (KPI's) ensuring that Health, Safety, and Environmental requirements are adhered to manage the team on technical best practice and establish standard policies and procedures whilst also mentoring and leading extrusion maintenance team. Implement and manage continuous improvement and modern manufacturing principles by highlighting deficiencies and recommending changes in training, working practices, and processes in co-ordination with SH Mechanical and DH mechanical.

Job Challenges:

• Immediate service engineer support & Spare parts
• Improve OEE for the machinery at the extrusion presses.
• Control the breakdown and increase productivity per person by developing people for multi-skill.
• SOP and SWI development for all the processes.
• Operation of LPG-fired log heating furnace, Heat treatment furnace, and optimizing its performance to reduce LPG consumption.
• Service and maintenance of both the Ageing Ovens on a continuous basis.
• Store-level inventory management
• Die manufacturing and correction unit machine management

4) Key Result Areas/Accountabilities:Key Result Areas/AccountabilitiesSupporting Actions Health, Safety, And Environment

• Co-coordinating with the safety team and ensuring statutory compliance full fill-100%.
• To ensure the use of PPE at workplaces.
• To identify unsafe work conditions and practices and take corrective action.
• To ensure regular safety audit to create a safe working environment.
• Promote awareness and practices of safety in the plant.
• Monitoring the functioning of critical equipment impacting environmental results.

Engineering & Maintenance strategy for Extrusion and Die shop.

• Effectively delegate any maintenance issues to be resolved on each shift and small projects to the right skills in the team, planning and managing effective works
• Adhere to daily and weekly checks to ensure the smooth operation of the site
• Develop a Planned Preventative Maintenance (PPM) schedule, ensure full preventative maintenance is carried out, plan in missed maintenance activities, and lead the team to deliver effectively
• Audit and ensure compliance with the engineering data systems
• Schedule both internal and external work(s) maximizing planned downtime and reducing unplanned downtime
• Manage the team to ensure machine availability
• Optimize equipment according to standard procedure, enhancing performance and product quality, ensuring the achievement of all Key Performance Indicators (KPIs)
• Develop clear accountability for maintenance material spend combined with a strategy to manage expenditure
• Perform root cause analysis and resolve problems
• Developing standard operating procedures for all maintenance work
• Ensuring that all maintenance processes are consistent with industry regulations and standards
• Drafting maintenance reports that help measure and improve the team's performance

Strategy and Development

• Contribute to the creation and implementation of best practice maintenance vision, strategy, processes, and procedures to aid and improve operational performance.
• Contribute to new business initiatives and projects and review and communicate the impact on Maintenance activities

Cost reduction
(To ensure effective utilization of resources to achieve the minimum cost of production)

• Identification and elimination of non-value-adding activities during PM of Press #1 & #2.
• To monitor the Power consumption of the presses and make an action plan to reduce it.
• To monitor store consumption trends and optimize the high-cost item and revise consumption norms for the low cost of production

Reliablity of the equipment

• Identify the chronic and sporadic problem of the press.
• Make an action plan to take corrective action to improve presses uptime for more production.

People Management

• Coach and develop a high performing Maintenance team that meets agreed objectives and which delivers best practice results, added value, and continuous improvements
• Report on achievement of targets and identify any actions required
• Ensure the delivery of the People Strategy within the area of accountability to my reportee
• Motivate and coach the team to operational success
• Monitor the completion of tasks and ensure good performance and record on appropriate systems
• Review, implement and update company records e.g. training matrices, performance reviews
• Communicate KPIs from the strategic annual plan so that each employee is aware

5) Job Purpose of Direct Reports:

Position TitleJob PurposePosition No. Supervisor

• Executing the works as per plan with the team, Involving and guiding the team during preventive maintenance, and Breakdown maintenance
• Verifying the daily, weekly, and monthly checklists on weekly basis
• Preparing/maintaining the spare parts for preventive maintenance
• Analyzing the breakdowns and finding the root cause and reducing the downtime to ensure the machine availability

Asst. Supervisor

• Servicing support like fabricating, welding, and renovating machinery

Electrical Technician

• Performing essential duties down the level.
• Performs electrical emergency, schedule, and unscheduled setup, installation, repair, and maintenance of machinery, equipment, and facility.
• Provides design and development recommendations, modifications, fabrications, and repair of electrical, mechanical, hydraulic, and pneumatic systems, assembly, sub-assembly parts, components, structures, etc.
• Comply with all the aspects of safety including but not limited to LTV as well as proper equipment start-up and shutdown producers
• Perform duties to support maintaining the plant safety and operations, quality, and other salutatory requirements.

Mechanical technician

• Performs mechanical emergency, schedule, and unscheduled setup, installation, repair, and maintenance of machinery, equipment, and facility.
• Provides design and development recommendations, modifications, fabrications, and repair of electrical, mechanical, hydraulic, and pneumatic systems, assembly, sub-assembly parts, components, structures, etc.

6) Relationships:

Relationship Type

(Internal or External) Frequency & Nature

1) SH Mechanical Maintenance Manpower requirement, CAPEX planning, updating status of machinery, equipment, and facilities. Taking a decision, consultation with strategy and development plan, safety requirements, and resources as required

2) DH Mechanical Maintenance
3) SH SCM
4) AH Projects
5) DH Die Shop
6) SH Safety
7) AH Stores
The requirement of maintenance supports seamless production, sustainable process sustainability, breakdowns, PM activities, and innovations.
Uninterrupted service support, vendor support, purchase and procurement support, spare parts, and consumables with supply chain management
Interacting with the project team for upcoming projects, and sustainable improvement projects. Working as a team along with the project by coordinating and ensuring the successful completion of the project as required
The requirement of maintenance supports seamless production, sustainable process sustainability, breakdowns, PM activities, and innovations
Work permit, JSA, safety requirements, etc.. as when required. Reporting behavior-based safety observations, incidents, and deviations
Maintaining minimum stock quantity, inspecting inward items, auditing store stocks,