SH Process / QA - Cast House

Business Metals

Unit Hindalco, Downstream Aluminium Extrusion

Location Kuppam, Andhra Pradesh

Poornata Position Number of the job Reports To Poornata Position No

Poornata Position Title of the job SH- Process & QA

Reports To Poornata Position Title Head Cast House

Function Project

Reports To Function Project

Department Cast House- Project

Reports To Department Project

Date of Last Updation/Approval

• Job Purpose To enable Cast House Plant to achieve full business potential by driving operational excellence, process efficiency, and product quality in upcoming Cast House dedicated to producing high-precision and aesthetic extrusion sections feedstock billets. The role will focus on developing and implementing robust process control systems, optimizing production workflows, and ensuring adherence to global quality standards.
• Dimensions: The project involves the participation of multiple technology suppliers, OEMs, EPC contractors, consultants, construction agencies, and service providers working simultaneously across various work fronts within the project site. Effective coordination and interface management among all stakeholders will be critical to achieving project objectives. Considering the aggressive project schedule, construction, installation, testing, and commissioning activities will be executed on a 24x7 basis across all three shifts, requiring robust planning, resource management, safety oversight, and continuous monitoring of project progress. As the project is being developed from the ground up, all essential project infrastructure and support facilities will need to be established, including temporary power supply, construction utilities, site offices, storage facilities, workshops, contractor amenities, communication networks, and logistics arrangements. Business/SBU/Unit Revenue Business Workforce Number Unit Workforce Number Function Workforce Number Department Workforce Number Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter Process and Quality systems need to be stabilized in sync with committed ramp up plan and ensuring consistent, continuous and sustainable improvement in 22KTPA Cast House.
• Job Context & Major Challenges:

Job Context Hindalco is establishing a new state-of-the-art Aluminium Extrusion facility at Kuppam, Chittoor District, Andhra Pradesh, to manufacture specialized aluminium extrusion products catering to high-growth sectors such as electronics, automotive, industrial machinery, and consumer durables. The proposed extrusion plant will have an installed production capacity of 7.5 KTPA. To support the billet requirements of the extrusion facility, a new Cast House Plant is being developed within the same campus. The Cast House will produce high-quality, specialized aluminium extrusion billets with a planned capacity of 22 KTPA, ensuring a reliable and integrated supply chain for downstream extrusion operations. The Kuppam facility is being developed as a strategic manufacturing hub for value-added aluminium alloy extrusion products, strengthening Hindalco's presence in key domestic and international markets while enhancing operational efficiency through integrated Cast House and Extrusion operations.

Key Plant Facilities and Equipment The project includes installation, commissioning, and integration of advanced process equipment and supporting utility systems, including:

Cast House

• Induction Melting Furnaces
• Electric Holding Furnaces
• Electric Homogenizing Furnaces
• Cooling Chambers
• Billet Casting Machine
• Degasser System
• Porus Tube Filtration (PTF) System
• Ceramic Foam Filtration (CFF) System
• Billet Handling and Sawing Machines.

Extrusion Plant

• 9" Aluminium Extrusion Press
• Ageing Ovens
• Fabrication and Cutting Machines
• Electrolytic Degreasing System
• Material Handling Systems

Utilities & Infrastructure

• Electrical Distribution Systems
• Instrumentation, Control and Automation Systems
• Compressed Air Systems
• Cooling Water Systems
• Fire Protection Systems
• Utility Networks and Auxiliary Facilities
• Plant-wide Material Handling and Logistics Systems

Job Challenges The new proposed Cast House & Extrusion Complex is a brownfield expansion of the exiting installation. This Facility is coming up at the adjacent land parcel which poses all the dynamic challenges like that of Greenfield expansion. There is no basic infrastructure available at the site. The necessary infrastructure needs to be conceived and erected for ensuring smooth Erection of the equipment. This role is responsible for driving Cast House quality excellence by closely engaging with customers to understand their requirements and translating them into robust production and quality control practices. The role provides technical guidance to operations teams in problem-solving, process optimization, and quality parameter control to achieve optimum output, zero-defect manufacturing, and superior customer satisfaction. It involves monitoring and analysing process performance, conducting inspections of inputs and outputs, identifying improvement opportunities, and implementing corrective and preventive actions across Cast House at Kuppam. A critical responsibility of the role is to ensure the highest standards of product quality through accurate measurement and control of key quality parameters such as Chemistry, Metallurgical parameters, Hydrogen (H?) levels, Inclusion Levels, thereby minimizing substandard extrusion billet generation and ensuring consistent compliance with customer specifications. The role also plays a vital part in maintaining safety, health, and hygiene standards during casting operations, ensuring adherence to approved furnace alloying practices, maximizing first-pass yield, and achieving excellence in Layer Process Audits (LPA). As the primary interface for customer quality management, the position requires regular customer interactions, site visits, material defect assessments, and proactive engagement with operations teams to ensure timely closure of customer complaints and CAPA (Corrective and Preventive Actions), thereby enhancing customer confidence and meeting Service Level Agreement (SLA) commitments.

• Lead day-to-day process & quality assurance activities at the project site, ensuring adherence to safety, quality, cost, and schedule requirements.
• Ensure all activities are executed in accordance with approved drawings, technical specifications, engineering standards, and project schedules.
• Coordinate closely with Civil, Mechanical, Electrical, Automation, Utilities, Process, and Commissioning teams to ensure seamless project execution and timely resolution of interface issues.
• Monitor construction progress, identify execution bottlenecks, implement corrective actions, and ensure compliance with project milestones.
• Supervise Installation and alignment of Cast House Equipment.
• Support the utilities team in the installation, calibration, testing, and commissioning of systems associated with Cast House Balance of Plant (BOP) facilities.
• Prepare daily and weekly execution plans, allocate manpower and resources, monitor contractor productivity, ensure material readiness, review work permits and method statements, and promptly resolve site technical issues.
• Lead and coordinate pre-commissioning and commissioning activities with OEMs and contractors to ssupport integrated plant startup and stabilization.
• Coordinate with OEMs, EPC contractors, consultants, and project stakeholders to review progress, verify work quality, approve measurement sheets, ensure contractor compliance with safety standards, and resolve technical and commercial issues.
• Maintain close engagement with the Procurement Team to ensure timely availability of materials, expedite critical procurements, monitor delivery schedules, and support effective project execution in line with project priorities and milestones.
• Ensure compliance with applicable safety standards, quality requirements, statutory regulations, and project governance processes throughout the project execution lifecycle.
• Absorbing new technologies, stabilizing processes, and fine-tuning operating parameters while simultaneously increasing production volumes.
• Managing stringent product qualification requirements for specialized products.
• Developing process capability with a relatively inexperienced workforce and addressing skill gaps in process control.
• Identifying and correcting design deficiencies while enhancing reliability, productivity, and operational performance beyond design capacity.
• Managing high production volumes while maintaining stringent quality control standards and zero-defect expectations.
• Responding to dynamic market requirements and increasingly stringent customer specifications in a highly competitive environment.
• Preparing and sustaining Cast House compliance with ISO 17025, ISO 9001, ISO 14001, and ISO 45001 standards.
• Prepare Annual Business Plans and detailed monthly product-mix plans and ensure adherence to agreed targets.
• Manage daily MIS and review Cast House process capability to drive continuous improvement.
• Ensure operational efficiencies and product quality meet customer requirements and business objectives.
• Drive implementation of best practices, process discipline, and SOP compliance across operations.
• Ensure uninterrupted availability of raw materials and consumables while supporting vendor development initiatives.
• Promote and ensure compliance with Safety, Health, and Hygiene standards during casting operations.
• Lead product and process qualification activities and ensure compliance with NABL, IMS, IATF, and customer audit requirements.
• Identify competency gaps and drive capability-building initiatives through structured in-house and external training programs for engineers.
• Support new product development initiatives by leveraging customer feedback, market intelligence, and process expertise.
• Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities Supporting Actions Help team in identification of the right Electrical equipment and systems Understand the requirements of the OEM supplied equipment. Identify the necessary utilities for the same. Select appropriate equipment. Compare the same with the international and internal standard. Decide on course to bridge gaps, if any. Lead & execute a construction team/contractor to complete the erection of various utilities at site for timely completion of the scheduled activity while meeting all the design specifications. Guide & execute with project team for timely completion of the project. Coordinate with OEMs / Erection and construction teams for timely completion. Prepare operational SOP for these items. Ensure safety practices are implemented at site. Aid the safety team in preparing safety guidelines for the project site. Implement SOP and safety protocol for each activity that needs to be carried out. Ensure that project personnel are trained and follow the safety guidelines issued to them. Audit the activity done by the project execution teams. Enforce the safety system with Permit to work mechanism for various types of jobs at site. Coordinate the activities of different project groups to meet the overall time and cost target. Monitor the project progress of each project group. Identify the critical activity and ensure its timely completion to complete the project as per the given schedule and as per the given cost. Meet the time and cost target of the assigned work area. Ensuring that the standards / specifications fixed by the Design team in adhered during the equipment erection. Understand the standards / specifications made by the design team. Implement on the project site and further on the shop floor those designs and specifications. Ensure proper handover and takeover of work regions to have a smooth workflow. Generate an operation & maintenance catalogue in the process. Through the interactions with OEMs and design teams develop the operation system – Manuals/ SOPs / Practices for the Plant Operation Implementation these systems during ramp up and running of the plant. Create a maintenance catalogue. Develop Operation & Maintenance practices Prepare operation & maintenance SOP/HIRA/SWI/Process flow as per production line requirement. Prepare maintenance planning/PM activities/KPI/Energy management plan & monitoring etc. Preparation of troubleshooting of unplanned breakdown of all equipment and plan for stabilization of plant during ramp up. Develop safe work practices and systems as per operation & maintenance practices of Hindalco.

• Job Purpose of Direct Reports:

Position Title Job Purpose

Position No. NA

• Relationships:

Relationship Type (Internal or External)

Frequency & Nature External OEMs / Contractors / Consultant / External Project Execution Teams – daily implementation of necessary steps for project completion Internal Internal Project execution teams – Daily implementation of necessary steps for project completion Head Cast House – Daily for reporting. Project Leadership – Daily for reporting.

• Organizational Relationships:

Position that It reports into Position and its peers (Nop = )

Position/s that reports into (Nop = ) Head Cast House SH Electrical & Automation (Cast House) = 1 SH Mechanical (Cast House) = 1 SH Mechanical (Fabrication) = 1 SH Process & QA (Fabrication) = 1 SH Electrical & Automation (Fabrication) = 1 SH Mechanical (Extrusion) = 1 SH Process & QA (Extrusion) = 1 SH Electrical & Automation (Extrusion) = 1 SH Utility Mechanical = 3 SH Utility Electrical = 3 NA

Declaration: This job description is a true reflection of the position -------------- Job Holder

Reports to Manager Name Date of Entry / Approval