Asst Manager - Electrolyte & Seperator Development

JOB DESCRIPTION — ANODIZING & SURFACE TREATMENT OPERATIONS MIL – Metal Fabrication Unit Thenepalle Job Title | Assistant Manager / Deputy Manager / Manager – Anodizing & Surface Treatment Operations | Department | Manufacturing Operations – Surface Treatment | Reports To | Plant Head / General Manager – Operations | Direct Reports | Shift Chemists, Anodizing Operators, ETP Operators, Lab Technicians | Location | Plant – Puthalapattu, Chittoor, Andhra Pradesh | Plant Configuration | 22-Tank Anodizing Line, 20 MT/Day Capacity | Employment Type | Full-Time, Permanent | Grade/Band | M08–M6A (as per company grading structure) | 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) KPI | Target | Measurement | First-Pass Yield | ≥95% | Daily | Rework Rate | <3% | Weekly | Throughput | ≥20 MT/day (post stabilization) | Daily | Coating Thickness Compliance | 100% within spec | Every load | Chemical Cost per MT | Within budget ±5% | Monthly | ETP Discharge Compliance | 100% within CPCB norms | Daily | Water Consumption per MT | Benchmark – 10% year-on-year | Monthly | Safety Incidents | Zero chemical incidents | Monthly | Customer Audit Score | ≥85% | Per audit | SOP Completion | 100% within 6 months | Milestone | 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 Competency | Required Level | Assessment | Sulphuric Acid Anodizing Process Control | Expert | Technical Interview | Chemical Titration & Lab Analysis | Expert | Practical Test | Pre-treatment (Etching/Desmutting) | Expert | Process Walk-through | ETP / RO / DM Plant Operations | Advanced | Case Study | Coating Thickness & Sealing Quality | Expert | Technical Interview | Defect Analysis (Staining/Burning/Patchiness) | Expert | Photo Analysis Test | Hazardous Chemical Safety / EHS | Advanced | Behavioral Interview | Rework/Stripping Process | Advanced | Technical Interview | Environmental Compliance (CPCB/SPCB) | Intermediate+ | Regulatory Knowledge | Water Balance & Utility Optimization | Intermediate+ | Case Study | Behavioral Competencies Competency | Expected Behavior | Process Discipline | Maintains chemical process parameters with zero deviation; treats specification limits as inviolable, not guidelines | Safety-First Mindset | Proactively identifies chemical hazards before incidents occur; never compromises safety for throughput | Analytical Rigor | Relies on data (titration, thickness, conductivity) for every decision; rejects intuition-based chemical management | Environmental Stewardship | Takes personal ownership of ETP compliance and waste management as a core responsibility, not an afterthought | Institution Builder | Creates SOPs, training materials, and control charts that make the process person-independent | Composure Under Chemical Emergencies | Remains calm and follows protocol during acid spills, bath contamination, or ETP upsets; never freezes |