DH Materials

Job Purpose
Job Purpose Description

Job 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 Though the technology is outdated, the press was make to perform efficiently through certain upgradations and modifications made to the machinery over the years.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 Reviews

Analyze Capex account statements and plan & implement corrective actions

Prepare 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 job

Preparation of capital proposals (RFA) as per approved Capex plan

Freez the technical specification of the equipments

Energy conservation aspect in the project conceptualization/evaluation

Prioritise and implement the energy saving projects

KRA10 Cost Management Develop new vendors for better cost advantage and achieving the organizational target

Ensure the successful implementaion JIT projects

Effetives Negotiate with vendors for better cost advantage and acheiving the organizational target

Ensure the cost effective method for transportation of materials

KRA11 WCM Coordinator Ensure and establish the WCM activities of the Plant

Propagate 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 cost

Negotiate and place the order for the new press

Import clearance of the press and accessories (strategic project)

Transportation/shipping of Project materials

Get the quotation of New Press, handling system and freeze the 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 cost

Negotiate and place the order for the new press

Import clearance of the press and accessories(strategic project)

Transporation/shipping of Project materials

KRA3 Project Implemention, monitoring & Review Plan, identify the resrouces required and place order for implementing the project

Prepare the time bound implementation plan for projects

Implementation and monitoring of Environment related aspects related with projects

Monitoring and evaluating the progress of the projects and take corrective actions whenever required

Erection and commissioning of new press

Stream lining of the press and auxiliary equipments and handing over for production

Plan and implementation of return based capex projects within approved budget and time frame

KRA4 Project Safety Management Monitor and eliminate the unsafe acts and conditions for zero accidents and incidents in the Project related job

Ensure the work permit system

Ensure the contract workers, especially working at heights for Medical check up

Ensure the safety practices in materials handling, availablility and usage of PPE's for project work

KRA5 Materials Management Developing new Vendors and assessing existing vendors for an existing Store Material supply

Getting competitive quotation

Effective functioning of Purchase Committe

Effectively Negotiate with vendors for better cost advantage and achieving the organizational target.

Finalizing the offer

Order placement and follow up

Import of Materials

Liaison with the ITD-Kolkata

Liaison with Accounts for Insurance

Disposal of retired assets with the help of E-Auction/advertise in news papaer

Sale of sawings and dross

Sale of scrap/retired assets items

Maintain the inventoy within budget

Ensure no production loss due to stock out

Ensure the availability of vital and critical spares

Dismanting and disposal of retired assests

Liaison with Accounts for insurance

Clearing of import

Logistics for incoming materials

MRR approval/Bill processing

Accounting of raw materials like billet and ingot and alloying elements

Ensure the meeting of internal and external customers as per plan

Ensure the inventory Analysis.

KRA6 Contract Management Managining the contract/contract workers for better resource utilization

Ensure the terms and conditions will be issued to suppliers as per corporate guidelines

Contracts will be issued to Approved /authorised contractors

Ensure contractor meets all the statutory obligations

KRA7 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 Unit

KRA8 Get Certification & Audit Management Ensure the AUdit, Progress review of the Management programmes and MRC as per Plan

KRA9 Conduct Management Review Committee & HRM Activity To maintain all the documents of ISO , ISO-14000, OHSAS-18000 relevant to projects Department

To amend necessary changes in documents, procedure and others if required

Close and take corrective action for all the NCR's during external or internal audits

Monitor and take corrective actions on the specific management programmes for EMS and OSHAS

To educate, motivate and involve employees in the department in fullfiiment of departmental objetives, prepare annual training plan

Maintain the administration of the projects and Materials department

Evaluate the training needs of Project and materials team and organize the training

Managining the contract workers for bettet resource utilization