Masters India - Head - Foil Mill Operations

• To lead and optimize end-to-end foil mill operations, ensuring high productivity, quality consistency, cost control, safety, and on-time delivery, while driving continuous improvement across rolling, slitting, finishing, and dispatch processes.

Scope of Operations:

• Foil Mill.
• Annealing furnaces.
• Slitters, separators, rewinders.
• Quality inspection and packing.
• Scrap generation and recovery control.
• Coordination with casting, QC, maintenance, and dispatch.

Key Responsibilities

• Production & Throughput Management.
• Plan and execute daily, weekly, and monthly production targets.

Optimize mill schedules for:.

• Gauge changes.
• Alloy mix.
• Slitting and packing efficiency.
• Maximize output while minimizing downtime and rejects.
• Ensure adherence to customer delivery timelines.
• Quality & Process Control.

Ensure consistent foil quality across:.

• Gauge tolerance.
• Surface finish.
• Pinholes.
• Oil residue.
• Tensile and elongation properties.
• Reduce rejections, downgrades, and customer complaints.
• Work closely with QC to improve first-pass yield.
• Implement root cause analysis for defects and breakdowns.
• Cost, Yield & Scrap Control.

Monitor and improve:.

• Yield %.
• Edge trim and process scrap.
• Downgrade material.
• Control rolling oil consumption, consumables, and spares.
• Drive cost per kg reduction initiatives.
• Coordinate scrap segregation, recovery, and recycling.
• Equipment & Maintenance Coordination.

Ensure optimal availability and performance of:.

• Rolling mills.
• Slitters.
• Annealing furnaces.
• Coordinate preventive and predictive maintenance.
• Reduce unplanned breakdowns and bottlenecks.
• Support upgrades, retrofits, and new equipment commissioning.
• Manpower & Shift Management.
• Manage supervisors, operators, technicians, and helpers.
• Define shift structures, skill matrices, and operator deployment.
• Drive productivity per man-shift.
• Identify training needs and develop shop-floor capability.
• Enforce discipline, SOP adherence, and safety culture.
• Safety, Compliance & Housekeeping.
• Ensure compliance with safety standards and statutory norms.
• Drive zero-accident culture.
• Implement SOPs, LOTO, and safe operating practices.
• Maintain high housekeeping and 5S standards across the mill.
• Continuous Improvement & Digitalization.
• Lead Lean / TPM / Six Sigma initiatives.
• Reduce changeover time, downtime, and wastage.

Support digital tools for:.

• Production reporting.
• OEE tracking.
• Quality traceability.
• Collaborate with IT / systems teams on MES or ERP adoption.
• Cross-Functional Coordination.

Coordinate with:.

• Casting / Rolling upstream teams.
• Quality and R&D.
• Maintenance and utilities.
• Stores and logistics.
• Sales and planning.
• Act as the single operational owner for foil mill performance.

Required Skills & Experience:

Must-Have:

• Strong hands-on experience in aluminium foil or cold rolling operations.
• Deep understanding of foil defects, rolling parameters, and annealing.
• Proven leadership in managing large shop-floor teams.
• Strong production planning and execution capability.
• Cost, yield, and efficiency mindset.