Asst Manager - Electrolyte & Seperator Development

Position Objective

To establish, stabilize, and manage the complete anodizing and surface treatment operations for a 22-tank anodizing line producing solar-grade aluminum frames at 20 MT/day capacity. The role holder will commission the anodizing line, establish chemical process controls, build and train the operations team, manage ETP/utilities compliance, and deliver consistently anodized profiles meeting Tier-1 solar customer quality standards for Motherson and Vikram Solar.

Core Responsibilities

A. Anodizing Process Management

• Own end-to-end anodizing process: degreasing, alkaline etching, desmutting, anodizing, sealing, and all intermediate rinses across 22 tanks
• Establish and maintain precise chemical concentration targets for each tank through systematic titration and lab analysis
• Control anodizing voltage, current density, and bath temperature to achieve consistent oxide film thickness (15-25 microns per customer specification)
• Manage process chemistry for sulphuric acid-based anodizing including acid concentration, aluminum content control, and contamination monitoring
• Achieve first-pass yield 95% and maintain colour consistency where applicable
• Develop and implement process parameter windows (control limits) for each tank in the line

B. Chemical Handling & Laboratory Operations

• Manage handling, storage, dosing, and replenishment of sulphuric acid, caustic soda, nitric acid, sealant chemicals, and proprietary additives
• Establish titration protocols and daily/shift lab testing schedules for all critical tanks
• Monitor and control chemical concentration, pH, conductivity, and dissolved aluminum across the process
• Implement chemical consumption tracking and cost optimization without compromising process quality
• Ensure proper chemical compatibility, segregation in storage, and MSDS availability at all handling points

C. Utilities & Environmental Systems

• Directly manage ETP (Effluent Treatment Plant) operations: neutralization, flocculation, sludge dewatering, and discharge compliance
• Oversee RO (Reverse Osmosis) plant and DM (Demineralized) water plant to ensure rinse water quality and process water standards
• Maintain water balance across the anodizing line-minimize freshwater consumption and maximize water recycling
• Manage chemical filtration systems, sludge disposal (as per hazardous waste regulations), and waste manifests
• Ensure full compliance with CPCB/SPCB norms and support environmental audit readiness

D. Rework & Rejection Management

• Analyze every anodizing rejection systematically: identify root cause (chemical, handling, pre-treatment, or extrusion-related)
• Manage controlled stripping and rework processes without damaging base profile dimensions
• Track rework volume, stripping chemical consumption, and yield recovery metrics
• Implement process corrections to prevent repeat defects and reduce rework below 3%

E. Shot Blasting Operations

• Oversee shot blasting preparation where required for specific surface finish specifications
• Control shot blasting parameters (media type, intensity, coverage) for consistent surface preparation
• Prevent over-blasting, under-blasting, and media contamination defects

F. Quality Assurance

• Ensure anodizing coating thickness compliance using eddy current / coating thickness gauges on every load
• Verify adhesion (tape test / boiling water test), corrosion resistance (salt spray / acetic acid test), and sealing quality
• Drive zero tolerance for surface finish defects: staining, burning, patchiness, discoloration, water marks, chemical contamination, handling scratches post-anodizing
• Support customer sample approvals, first-article inspection, and ongoing PPAP maintenance

G. Safety & EHS Compliance

• Establish and enforce acid handling SOPs: PPE requirements (acid-resistant suits, face shields, chemical gloves), spill containment, emergency eyewash/shower stations
• Conduct regular hazardous chemical safety training for all anodizing personnel
• Maintain emergency response protocols for acid spills, chemical burns, and fume exposure incidents
• Ensure full compliance with Factories Act, environmental regulations, and customer EHS audit requirements

H. Production Management & Systems

• Drive throughput optimization to achieve 20 MT/day rated capacity within 6 months of commissioning
• Manage jig design, loading density, and cycle time optimization for maximum rack utilization
• Establish OEE tracking, shift management protocols, and production planning adherence
• Deploy and sustain 5S, visual management, and standard work across the anodizing shop

I. Leadership & Team Building

• Build the anodizing team from scratch: hire and train shift chemists, operators, ETP operators, and lab technicians
• Create comprehensive training modules covering anodizing chemistry fundamentals for all operators
• Independently manage customer audits and qualification processes
  
• Support plant commissioning: tank installation validation, chemical charging, process proving, and customer sample approvals

Key Performance Indicators (KPIs)

Candidate Profile & Qualifications

Education

• B.E. / B.Tech in Chemical Engineering, Metallurgical Engineering, or Electrochemistry (mandatory)
• B.Sc. Chemistry with extensive anodizing line experience (acceptable for AM level)
• M.Tech in Surface Engineering / Corrosion Science or MBA in Operations (preferred)

Certifications (Preferred)

• NACE / SSPC Coating Inspector certification
• Six Sigma Green Belt
• ISO 14001 / ISO 45001 Internal Auditor
• Hazardous Chemical Handling / HAZMAT certification

Experience

• 8-15 years of progressive experience in aluminum anodizing / surface treatment operations (mandatory)
• Minimum 2-3 years in a supervisory or managerial capacity independently running an anodizing line
• Direct experience with multi-tank (15+ tank) sulphuric acid anodizing lines
• Greenfield setup or major line commissioning experience is a strong advantage
• ETP/RO/DM plant hands-on management experience (mandatory, not just oversight)

Must-Have Industry Background

• Aluminum anodizing for solar frames, architectural profiles, or industrial applications
• Multi-tank continuous/batch anodizing line operations (not small job-shop anodizing)

Preferred Source Companies

• Jindal Aluminium (anodizing division), Hindalco downstream units
• Alom Extrusions, Maan Aluminium, Salman Group
• SAF Aluminium (anodizing specialist), Bhoruka Extrusions
• Aluwind Architectural Products, Alstrong Enterprises
• Any Tier-1 solar frame manufacturer with in-house anodizing

Technical Competency Matrix

Behavioral Competencies