Shop Head - Die Manufacturing

Job Overview

The position is responsible for planning, overseeing, and controlling manufacturing operations to ensure the availability of high-quality extrusion dies. The role involves ensuring manufacturing activities are conducted within the budget, within a safe work environment, and focuses on setting up an advanced die manufacturing facility with industry-leading equipment to support scalability and productivity improvements.

Role Context and Challenges

Hindalco, India's largest aluminum manufacturer, operates multiple plants with extrusion dies designed mostly from empirical experience at each location. Technological advancements and market demands require upgrades in die design and manufacturing capabilities using cutting-edge equipment. This role emphasizes standardizing practices and technology transfer to enhance plant potential and mastery over die design and manufacturing processes. The job involves utilizing CAD systems and simulations for critical die design and manufacturing, adding value to design, production, and repair of dies to maintain high product quality. Continuous innovation to boost team productivity and efficiency is essential.

Key Responsibilities

• Manufacture extrusion dies according to design specifications maintaining world-class standards.
• Minimize die development time to global standards while managing costs.
• Continuously upgrade die manufacturing processes based on market developments.
• Optimize resource utilization including manpower and workflows through studies and process improvements.
• Ensure workplace safety by enforcing use of personal protective equipment, counseling workers, and maintaining safe conditions.
• Implement autonomous maintenance with routine machine inspections by operatives.
• Manage technology transfer agreements, ensure adoption of industry best practices, and maintain partner relationships.
• Maintain customer-centric focus by meeting delivery schedules, supporting new product development, and overseeing sample approval processes.
• Achieve high-quality standards aiming for six sigma levels within one year of establishing the central die shop and organize technical training for staff.
• Drive cost reduction through enhanced productivity, utilization of quality steel, error elimination, and leveraging digital technologies for monitoring KPIs.
• Develop and train staff via multi-skilling, grievance resolution, appraisals, and counseling for career growth.
• Standardize die manufacturing processes and practices to reduce costs and enhance consistency.
• Lead digitalization initiatives including development of manufacturing execution systems (MES) and enterprise resource planning (ERP) integration for the new die shop, adhering to project timelines.

Additional Information

This role entails responsibility for building a multi-skilled workforce prepared for diverse machine centers, fostering a culture of continuous improvement through structured research and training, and piloting fully automated job loading/manufacturing systems in the future.