Assistant General Manager WRM

Department

Role Purpose

1.2 MTPA Wire Rod Mill

Key Responsibilities

1. Operations Management

• Plan and execute daily/monthly production of wire rods and bars as per rolling schedules.
  
• Oversee mill operations: reheating furnace, roughing, intermediate, finishing stands, laying head, pinch rolls, cooling conveyor, shears, bar rolling section.
  
• Ensure optimal mill utilization with minimal downtime and maximum rolling yield.
  
• Manage rolling campaigns, groove schedules, pass design, and sequence planning.
  
• Monitor product dimensions, surface finish, coil formation, and mechanical properties.
  

2. Quality Assurance & Process Control

• Ensure wire rod and bar products meet mechanical, chemical, and dimensional standards.
  
• Control process parameters: reheating temperature, rolling speed, water box cooling, laying head speed, and controlled cooling.
  
• Work closely with Quality Assurance for defect analysis (cobble, scale, cracks, laps, fins, underfills) and implement corrective measures.
  
• Drive Six Sigma/Lean/TPM initiatives for quality and yield improvement.
  

3. Maintenance & Reliability

• Oversee preventive and predictive maintenance of mill stands, guides, roller bearings, gearboxes, drives, laying heads, pinch rolls, and cooling beds.
  
• Ensure spares planning, inventory management, and availability of critical consumables (rolls, guides, bearings, nozzles, etc.).
  
• Monitor and improve roll consumption, bearing life, and equipment reliability.
  
• Collaborate with Mechanical, Electrical, and Instrumentation teams for uptime maximization.
  

4. People Management

• Lead and mentor shift in-charges, operators, and maintenance teams.
  
• Build workforce technical skills through structured training programs.
  
• Develop team culture emphasizing accountability, ownership, and performance.
  

5. Safety, Health & Environment (SHE)

• Ensure strict adherence to safety norms during mill operation and maintenance.
  
• Enforce safe practices in reheating furnace, rolling stands, laying head, coil handling, and bar cutting operations.
  
• Drive a “zero accident” culture and ensure compliance with statutory and ISO standards.
  
• Promote energy efficiency and environmentally sustainable rolling practices.
  

6. Cost & Resource Management

• Monitor and control consumption of rolls, guides, power, gas, water, and lubricants.
  
• Implement cost reduction projects through yield improvement, scrap minimization, and energy optimization.
  
• Achieve lowest cost/ton rolled through efficient resource utilization.
  

7. Coordination & Reporting

• Coordinate with upstream (SMS/CCM) for billet supply and downstream (Dispatch/Marketing) for customer requirements.
  
• Ensure rolling schedules are aligned with production planning and market demand.
  
• Prepare daily/monthly reports on production, quality, downtime, yield, and cost performance.
  
• Present MIS dashboards and improvement initiatives to senior management.
  

Key Performance Indicators (KPIs)

• Production achievement vs. rolling plan (tons/month).
  
• Mill yield (%).
  
• Energy consumption (kWh/t, Nm/t).
  
• Rolling speed and mill utilization (%).
  
• Product rejection/defect rate (%).
  
• Roll and guide consumption norms.
  
• Safety performance (LTI, MTI, near misses).
  
• Cost/ton of rolled product vs. budget.
  

Qualifications & Experience

• Education

  : B.E./B.Tech in Metallurgy / Mechanical / Electrical Engineering.

• Experience

  : 15–20 years in long product rolling, with at least 7–8 years in Wire Rod/Bar Mill leadership roles.
• Proven track record in high-speed rolling operations, groove/pass design, and process control.
  
• Experience in advanced WRM technologies (Morgan, Danieli, SMS Meer, etc.) preferred.
  

Competencies & Skills

• Strong technical knowledge of rolling mill operations (wire rod & bar).
  
• Expertise in roll pass design, thermo-mechanical rolling, controlled cooling, and product metallurgy.
  
• Problem-solving and troubleshooting ability in high-speed rolling.
  
• Leadership, team building, and communication skills.
  
• Knowledge of automation (PLC, Level-2, HMI systems).
  
• Strong focus on safety, quality, and cost.