Senior Manager - Production (P - 7907)

Job Title: -Senior Manager - Production

Job Description: -

We are looking for an experienced Aluminium Extrusion Operations professional to lead end-to-end extrusion operations for a manufacturing facility producing solar module frames and structural aluminium profiles.

Key Responsibilities:-

Aluminium Extrusion Operations

• Lead end-to-end operation of the 1400-ton aluminium extrusion press across all shifts.
• Optimize extrusion parameters including ram speed, billet temperature, container temperature, pressure, and exit temperature.
• Handle extrusion of 6005 and 6063 aluminium alloys while maintaining required dimensional and surface quality.
• Troubleshoot extrusion defects such as die lines, surface tears, profile distortion, speed cracks, twisting, bow, and other surface defects.
• Drive productivity and OEE improvement across the extrusion operation.
• Ensure stable production output while maintaining customer-specific quality requirements.

Billet & Metallurgy Management

• Supervise billet cutting, charging, and heating operations.
• Ensure correct process parameters for 6005, 6063, and other 6xxx series aluminium alloys.
• Monitor billet temperature uniformity and incoming material quality.
• Coordinate with Quality and Procurement teams for raw material quality issues.
• Ensure proper metallurgical and process controls to achieve required mechanical properties.

Die & Tooling Management

• Manage the complete extrusion die lifecycle, including receipt, trial, correction, production deployment, maintenance, and retirement.
• Coordinate with die manufacturers for die correction and profile accuracy.
• Monitor die life and maintain die history and performance records.
• Manage dummy blocks, container liners, stems, and other extrusion tooling.
• Optimize tooling inventory, die rotation, and tooling costs.

Downstream Operations

• Manage puller, run-out table, stretcher, cutting, and profile handling operations.
• Ensure required straightness and cut-to-length accuracy.
• Establish proper handling and stacking practices to prevent scratches, drag marks, dents, and other surface damage.
• Ensure smooth material flow from extrusion through downstream processes.

Aging & Heat Treatment

• Control artificial aging cycles for 6005-T5/T6 and 6063-T5/T6 profiles.
• Monitor aging furnace temperature, time, loading pattern, and process uniformity.
• Ensure required hardness and mechanical properties are consistently achieved.
• Troubleshoot under-aging, over-aging, and furnace-related quality issues.

Quality & Customer Requirements

• Ensure profiles meet customer drawings, dimensional tolerances, surface finish, and quality requirements.
• Drive a zero-defect / zero-escape approach for solar-grade aluminium profiles.
• Lead RCA, CAPA, FMEA, and corrective action activities for quality issues.
• Support customer audits, first-article inspections, PPAP, and process validation.
• Coordinate with Quality teams to address customer complaints and prevent recurrence.

Production Management & Continuous Improvement

• Manage production planning, shift operations, manpower deployment, and production targets.
• Track and improve OEE, productivity, yield, scrap, rejection, and downtime.
• Conduct downtime and rejection analysis and implement corrective actions.
• Implement TPM, 5S, Kaizen, Lean Manufacturing, and continuous improvement initiatives.
• Establish and maintain production SOPs, work instructions, checklists, and control plans.
• Drive improvement in metal recovery and extrusion yield.

Cost & Productivity Management

• Monitor extrusion yield and metal recovery.
• Control tooling, consumable, energy, and production costs.
• Analyze scrap and rejection through Pareto analysis.
• Implement cost reduction and productivity improvement initiatives.

Team Leadership

• Build and develop the extrusion production team.
• Recruit, train, and develop shift engineers, operators, and technicians.
• Prepare competency matrices and training plans.
• Provide technical guidance for extrusion process and troubleshooting.
• Lead customer audits, management reviews, and plant walkthroughs.

Greenfield / Commissioning

• Support commissioning of the 1400T extrusion press and associated downstream equipment.
• Establish operating parameters, SOPs, checklists, and control plans.
• Conduct equipment trials, process validation, and production stabilization.
• Build the production team and establish operational systems for the new facility.