Operations Manager

Position Objective

To lead the end-to-end aluminum extrusion operations-from billet preparation through aging-for a manufacturing facility producing solar module frames and structural profiles. The role holder will commission the 1400-ton extrusion press, establish all operating procedures, build and train the production team, and deliver stable, high-quality output meeting solar industry specifications for Tier-1 customers including Motherson and Vikram Solar.

Core Responsibilities

A. Extrusion Press Operations

• Own the complete operation of the 1400-ton aluminum extrusion press across all shifts
• Optimize extrusion parameters: ram speed, billet temperature, container temperature, pressure, and exit temperature for 6005 and 6063 alloys
• Manage die loading/unloading sequences, container alignment, and stem/dummy block integrity
• Achieve target extrusion speeds while maintaining profile dimensional accuracy within solar frame tolerances
• Conduct systematic troubleshooting of press-related defects: die lines, surface tears, profile distortion, speed cracks
• Drive productivity improvement programs targeting OEE 78% within the first 12 months

B. Billet Handling & Metallurgy

• Supervise billet cutting, charging, and heating operations with precise temperature control
• Ensure alloy-specific handling protocols for 6005 (higher strength, tighter process window) and 6063 (formability-focused) billets
• Monitor billet homogenization quality and coordinate with raw material procurement on incoming quality
• Maintain billet temperature uniformity to prevent hot shortness, surface defects, and inconsistent mechanical properties

C. Tooling & Die Management

• Manage the complete die lifecycle: receipt, nitriding, trial, correction, production deployment, and retirement
• Work closely with die manufacturers on correction feedback for profile accuracy and surface finish
• Monitor die life, maintain die history records, and optimize die rotation for cost efficiency
• Oversee dummy block, container liner, and stem maintenance schedules
• Maintain tooling inventory with min/max stock levels and lead time visibility

D. Downstream Operations

• Manage puller operation, run-out table handling, and single stretcher operations for profile straightness
• Ensure cut-to-length accuracy within ±1 mm and prevent handling damage through proper profile support and stacking procedures
• Establish handling protocols that prevent scratches, drag marks, and surface damage on solar-grade profiles

E. Aging Process

• Define and control artificial aging cycles (time, temperature, ramp rate) for 6005-T5/T6 and 6063-T5/T6 tempers
• Ensure consistent hardness achievement across furnace loads (target: 6063-T5 ≥10 HW, 6005-T5 ≥12 HW per customer specs)
• Monitor aging furnace uniformity and loading patterns to prevent under-aging or over-aging

F. Quality Assurance Support

• Ensure all profiles meet dimensional tolerances per solar frame drawing specifications
• Drive zero-escape culture for surface defects: extrusion lines, die marks, twisting, bow, bend, drag marks, scratches
• Support customer audit readiness and first-article inspection processes
• Own root cause analysis for all quality deviations and implement effective CAPA

G. Production Management & Systems

• Drive OEE tracking and improvement across all press shifts
• Lead production planning adherence, shift management, and manpower deployment
• Conduct systematic downtime analysis and implement countermeasures
• Deploy and sustain TPM, 5S, Kaizen, and Lean Manufacturing practices on the shop floor
• Establish and maintain all production SOPs, work instructions, and control plans

H. Commercial & Cost Management

• Track and improve extrusion yield (metal recovery), targeting ≥85% billet-to-finished-profile yield
• Monitor and optimize tooling cost per kg, consumable consumption, and energy cost per ton
• Drive scrap reduction programs with systematic Pareto analysis of rejection categories

I. Leadership & Team Development

• Build the extrusion team from scratch: recruit, train, and develop shift engineers and operators
• Create competency matrices and training calendars for all operational roles
• 
  Independently manage customer audits, visitor walkthroughs, and management reviews
• Support plant commissioning activities including equipment trials, process validation, and customer PPAP

Key Performance Indicators (KPIs)

Candidate Profile & Qualifications

Education

• B.E. / B.Tech in Mechanical Engineering, Metallurgical Engineering, or Production Engineering (mandatory)
• M.Tech in Metallurgy / Materials Science or MBA in Operations (preferred, not mandatory)

Certifications (Preferred)

• Six Sigma Green Belt or Black Belt
• TPM Practitioner / Lean Manufacturing Certification
• Internal Auditor - ISO 9001:2015 / IATF 16949

Experience

• 10-15 years of progressive experience in aluminum extrusion operations (mandatory)
• Minimum 3 years in a supervisory/managerial capacity running a press independently
• Greenfield/commissioning experience is a strong advantage
• Solar frame or automotive aluminum profile manufacturing experience preferred

Must-Have Industry Background

• Aluminum extrusion - solar frames, architectural profiles, industrial profiles, or automotive profiles
• Experience with 6xxx series alloys (6005, 6063, 6061) is non-negotiable

Preferred Source Companies

• Jindal Aluminium Ltd., Hindalco (Renusagar/Hirakud/Aditya Birla Group units)
• Maan Aluminium, Alom Extrusions, Century Extrusions
• Bhoruka Extrusions, Sudal Industries, Rock Extrusions
• Arconic, Norsk Hydro, Constellium (for candidates with international exposure)
• Solar frame specialists: Alom Group, Salman Group, Akash Aluminiums

Technical Competency Matrix

Behavioral Competencies