AH Powder Coating Specialist

Overview

This role focuses on overseeing the production and process workflows in the powder coating department, ensuring all specifications are met and deadlines are adhered to for both internal and external customers. Coordination with related departments, laboratory chemists, and shift supervisors is essential.

Business and Workforce Details

• Overall business revenue: 403 crores
• Total workforce: 679 employees, including various management and contract categories
• Department workforce for powder coating: 27 personnel (1 MS, 7 LMS, 19 contract)

Department Metrics

• Budget: 5.2 crores
• Revenue: 5.8 crores
• Volume handled: 816 tons
• Annual capacity: 6250 tons
• Major customers: Schueco, Alumax, Titan, Olympic, Ecoppia, Corob
• Market segments: Formworks, Industrial, Building & Construction, with 20% export business

Context and Challenges

The aluminum market is rapidly expanding globally with increasing demand for lightweight extruded products. This facility in Kuppam, Andhra Pradesh, is unique globally by integrating mill finish, anodizing, powder coating, and fabrication under one roof. The unit handles complex product profiles with specialized machinery and skilled teams serving diverse sectors such as construction, industrial, exports, automotive, and solar.

Key challenges include optimizing cost and efficiency in powder coating and managing frequent product changeovers due to low-volume orders.

Key Responsibilities

• Promote a zero-harm safety culture and ensure a secure work environment through regular monitoring, training, and reporting.
• Maintain and update fabrication processes to ensure safe and environmentally friendly operations.
• Conduct frequent shop floor audits to identify risks and enforce machine safeguarding.
• Implement energy-saving measures and conduct 5S training and audits to maintain workplace organization.
• Drive profitability through efficient manpower and equipment utilization; coordinate production planning closely with sales and PPIC teams.
• Monitor powder coating production daily, manage material availability, and ensure quality compliance.
• Maintain accurate production records, KPIs, OEE tracking, and inventory management including consumables and stock.
• Facilitate internal audits ensuring all safety, quality, and production documentation is accurate and complete.
• Coordinate across departments to resolve process issues and avoid production bottlenecks.
• Provide leadership feedback and performance evaluations for supervisors and operators.
• Plan for continuous improvement and set new operational goals aligned with business growth strategies.