Ah PLC Automation

**Designation**:Senior Engineer

**Updated**:December 06, 2024

**Location**:Andhra Pradesh, India

**Organization**:Metals

**Job Purpose**:
To design, troubleshoot, modify control programs for fault finding in automated electrical machines and systems, maintain spare for machine reliability, improve machine efficiency by reducing downtime, Plan and execute electrical activity.

**Job Context & Major Challenges**:
Job Context: To check, repair and service automated electrical machines by checking software programs, perform fault diagnostics & modify programs to ensure machinery runs smoothly and reliably by maintaining spares.
The global aluminium market is valued at USD 87.84 billion in 2021 and is expected to grow 7.5 % (CAGR) from 2022 to 2030. The increase in demand for lightweight and durable extruded products is driving the growth. Top aluminium extruders are investing and creating tough competition.
Hindalco Industries Limited have acquired the extrusion business of SAPA located at Kuppam, Andhra Pradesh with effect from 01 Feb 2022 through Business Transfer Agreement
This plant is the first of its kind, across the globe to have mill finish, anodized, powder coated, fabricated products manufactured under one roof. The profiles developed and manufactured are highly complex in nature, having critical die designs, challenging operations, involve highly skilled technicians, special machinery, and processes. This unit has two 8-inch press with a capacity of 16,000 TPA, anodizing 2500 TPA, powder coating 3200 TPA along with various fabrication machinery like manual & robotic welding, CNC cutting & machining centers, Flaring & collaring, assembly lines serving for Building & Construction (25%), Industrial (40%), Exports (25%) Automotive (7%), and Solar segments (3%).
The unit is increasing its business in automated warehouse system, premium anodizing finish products (exports), Solar energy and automotive (domestic) segments by increasing utilization of existing facility with additional shifts for continuous operation, setting up new fabrication facility, additional anodizing tanks and a brand-new extrusion press.
This role Engineer Head PLC in M/S Hindalco Industries Ltd, Kuppam is necessary to troubleshoot & fault find Automation related issues by checking software programs, HMI and Drives, also to ensure machine healthiness and availability for production by ensuring all spares for continuous operation of the plant.

Job Challenges: '¢ Spare procurement,
'¢ Understanding new technologies in control equipment's,
'¢ various Programming software's based on Manufacturer

**Key Result Areas**:
**KRA (Accountabilities) (Max 1325 Characters)**

**Supporting Actions (Max 1325 Characters)**
- KRA1- Automation & Motion Control:
Understand, program, and diagnose faults in Automated Electrical equipment- Execute new programs for the benefit of the user understanding user requirements
- Design and develop programs and implement it.
- Understand Electrical schematics and troubleshoot system errors.
- Fault findings in Drives & Servo drives.
- Program backup & download.- KRA2- Visualization:
Design and develop HMI screens, alarms & trends.- Add alarms for better fault findings
- Visualize automated systems.- KRA3- Understanding Maintenance goals:
To keep Maintenance KRA under limits- . Improve Machine availability for production
- Perform PM & Identify faults which effects machine downtime.- KRA4- Spare Management & Tracking:
Identify critical spares of each machine and maintain its availability.- . identify spares of each machine
- Check availability of spare.
- Categorize spare based on level of importance.
- Maintain documentation of all areas,
- Request and obtain offers from product manufacturers and vendors.
- Raise & track product indent.
- Check received material at stores and ensure it is as per the Invoice.- KRA5- Uphold Company Safety:
Always follow company's safety procedures during work.- . Focus on safety before start of any work
- Follow Safety procedures and documentation to execute work safely.
- Ensure our team is following Safety during the work.
- Being also responsible as a Task Force team.
- A member of Emergency response team (ERT).
- participate in Approach and Coach held by Company- KRA6- Cost reduction:
Identify cost cutting activities in Automation.- . Figure out areas of cost reduction.
- leverage skills to identify cost cutting methods and implement.- KRA7- Electrical Machinery/Activity:
Reduce downtime of machinery and plan works- . Availability of Machines all the time by performing timely maintenance
- Identify and maintain critical spare
- Plan and execute works.- KRA8- Training to team members:
Provide hands-on training- . Provide Programming troubleshooting training to team members helps us to save breakdown time**Qualifications**:
Bachelors in Engineering

**Minimum Experience Level**:
3-6 Years

**Report to**:
Officer