Job Purpose
Job Purpose DescriptionJob Context & Major Challenges
Alupuram Works established in 1943 as an Aluminium Smelter at Cochin in the State of Kerala. Presently the Extrusion Plant has two presses and Cast House has hot top casting and conventional casting facility. Extrusion presses were installed in 1955 and 1965 respectively. Annual production capacity of the plant is about 13800 tons of extrusions per annum. Though the technology is outdated, the press was make to perform efficiently through certain upgradations and modifications made to the machinery over the years. Casting Plant supply the raw materials in the form of billets for the extrusion requirement.The competition in the extrusion business is extremely severe, since the installed capacity is double than the market demand. Plant offers wide range of alloys and shapes in India. Business concentrates on value added applications such as Defence, Bridges, Automobile, Marine and other electrical applications. Since the market is very much cost sensitive, it is inevitable to produce the extrusions at an affordable cost to the customers. Through various cost reduction initiatives, the cost was kept under control over the years and the time has come now to expand the facilities in order to increase the volume as well as to bring down the overall cost. Also in India, this plant is the only plant, which supplies speciality, and complex profiles to all sectors. Considering the potential for large volume of value added and speciality products in India as well as in the overseas market, additional presses being proposed to increase the production from 13800 TPA to 25800 TPA. Being a Brown field expansion, the project is very critical in terms of making suitable lay out and installation of machinery solely imported, coordination with the overseas supplier including organizing for inspection or organising for dismantling in case if it is a second hand press.Since most of the components of equipment are imported, Materials deparment plays a major role for sourcing materials from different corners of the world. Also the Materials Management plays a major role in getting the imported raw materials from time to time in the form of scrap or billets. Some of the major material area are: The Die steel, which required for making dies, different kinds of packing materials required for operation and all kind of cutting tools required for operation Die shop, which posses all kind of tool room machine.Attitude of the workforce have undergone considerable change and the quality culture is entrenched in the works through continual improvements and team working.Major Challenges
Conceptualize, plan, procure and implement return based and major non-return based capex projects within the approved time and cost including getting legal and other permissions.Materials management includes, purchase , stores, imports of spares, dismantling/disposal of assests and scrap, clearance of goods from customs for efficient running the production of cast house and extrusion press.Meeting all the statutory requirements and legal clearance which are required for the smooth installation and commissioning of the project. Freezing the technical specification, lay out and implementation of new extrusion press, handling system, down stream equipments like furnaces and stretchers and utilities like water and Pneumatic system including getting legal and other permissions.Effective and time bound plan for procuring items pertaining to the new press and down stream equipment/capital goods without cost and time over run.As a Management Representative and WCM coordinator, it is required toPlan, Coordinate, Implement & Review IMS (Integrated Management Sysem) and WCM activities for the efficeint running of the Plant.Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 Capex Planning - Project Engineering Prepare Annual & Rolling Capex Plan of the Unit.Ensure Monthly Capex ReviewsAnalyze Capex account statements and plan & implement corrective actionsPrepare the design, drawings and schedule of quantities for the project related work including building Liaison with Factory Inspectorate and Municipality/Government Officials for getting the permit for the project related jobPreparation of capital proposals (RFA) as per approved Capex planFreez the technical specification of the equipmentsEnergy conservation aspect in the project conceptualization/evaluationPrioritise and implement the energy saving projectsKRA10 Cost Management Develop new vendors for better cost advantage and achieving the organizational targetEnsure the successful implementaion JIT projectsEffetives Negotiate with vendors for better cost advantage and acheiving the organizational targetEnsure the cost effective method for transportation of materialsKRA11 WCM Coordinator Ensure and establish the WCM activities of the PlantPropagate WCM concepts through traininig, team competitions, awards (5S, kaizen awards etc). To facilitate the WCM team in implementing in actions, motivate the teams to acheive WCM targets. Ensure the WCM steering committee meeting and Audits. Liaisoning with Corporate WCM. To facilitate tje Unit for Chairman's WCM awards-Conducting Pre assessments, Position paper preparations etc.,. To encourage the culture of WCM in the department. To coordinate activities connected with implementation of JIT concepts with projects. To provide awareness on WCM related concepts. Implementation and minitoring of spefici KMFAs under WCM movement.KRA2 Vendor Development & Project Scheduling Developing new Vendors and assessing existing vendors for projects related job.Get the quotation of New Press, handling system and freeze specification.Procurement of equipments, materials, consumables and capital goods within the approved amount.Ensure reliable, consistant suppliers and equipments through proper sourcing within the budgeted costNegotiate and place the order for the new pressImport clearance of the press and accessories (strategic project)Transportation/shipping of Project materialsGet the quotation of New Press, handling system and freeze the specificationProcurement of equipments, materials, consumables and capital goods within the approved amountEnsure reliable, consistant suppliers and equipments through proper sourcing within the budgeted costNegotiate and place the order for the new pressImport clearance of the press and accessories(strategic project)Transporation/shipping of Project materialsKRA3 Project Implemention, monitoring & Review Plan, identify the resrouces required and place order for implementing the projectPrepare the time bound implementation plan for projectsImplementation and monitoring of Environment related aspects related with projectsMonitoring and evaluating the progress of the projects and take corrective actions whenever requiredErection and commissioning of new pressStream lining of the press and auxiliary equipments and handing over for productionPlan and implementation of return based capex projects within approved budget and time frameKRA4 Project Safety Management Monitor and eliminate the unsafe acts and conditions for zero accidents and incidents in the Project related jobEnsure the work permit systemEnsure the contract workers, especially working at heights for Medical check upEnsure the safety practices in materials handling, availablility and usage of PPE's for project workKRA5 Materials Management Developing new Vendors and assessing existing vendors for an existing Store Material supplyGetting competitive quotationEffective functioning of Purchase CommitteEffectively Negotiate with vendors for better cost advantage and achieving the organizational target.Finalizing the offerOrder placement and follow upImport of MaterialsLiaison with the ITD-KolkataLiaison with Accounts for InsuranceDisposal of retired assets with the help of E-Auction/advertise in news papaerSale of sawings and drossSale of scrap/retired assets itemsMaintain the inventoy within budgetEnsure no production loss due to stock outEnsure the availability of vital and critical sparesDismanting and disposal of retired assestsLiaison with Accounts for insuranceClearing of importLogistics for incoming materialsMRR approval/Bill processingAccounting of raw materials like billet and ingot and alloying elementsEnsure the meeting of internal and external customers as per planEnsure the inventory Analysis.KRA6 Contract Management Managining the contract/contract workers for better resource utilizationEnsure the terms and conditions will be issued to suppliers as per corporate guidelinesContracts will be issued to Approved /authorised contractorsEnsure contractor meets all the statutory obligationsKRA7 Management Representative (MR) of the Plant Plan, coordinate and implementy IMS (Intergrated Management Sytstem-ISO 9001, ISO 14001, OHSAS 18001 activities and maintain the certification of the UnitKRA8 Get Certification & Audit Management Ensure the AUdit, Progress review of the Management programmes and MRC as per PlanKRA9 Conduct Management Review Committee & HRM Activity To maintain all the documents of ISO 9001-2000, ISO-14000, OHSAS-18000 relevant to projects DepartmentTo amend necessary changes in documents, procedure and others if requiredClose and take corrective action for all the NCR's during external or internal auditsMonitor and take corrective actions on the specific management programmes for EMS and OSHASTo educate, motivate and involve employees in the department in fullfiiment of departmental objetives, prepare annual training planMaintain the administration of the projects and Materials departmentEvaluate the training needs of Project and materials team and organize the trainingManagining the contract workers for bettet resource utilization
