COE - Head Process Care & Quality

Daily Process Care & Quality Control

• Ensure achievement of monthly quarterly and annual P&B targets of PBUs and AETs across the Vertical.
• Plan & control the direct and indirect costs associated with PBU & AET operations monitor expenses against budget in order to achieve budgeted efficiency better cost control and improve overall profitability.
• Ensure actions to control inventory of raw materials WIP & finished anodes and achieve working capital for the day through regular Inventory review & Scrap management in line with annual working capital plan.
• Identify gaps in various utilities & their consumption (Steam Power LSHS & fuel) propose schemes and partner with AETs for their deployment.
• Drive flawless daily work management system by implementing PBUT AET DMT & COEs excellence standards across PBUs and ensure adherence to quality parameters.
• Set & communicate clearly defined KPIV & KPOV (Key Performance Input / Output Variables) of process care to AETs & DMTs with all the related costs.
• Establish Daily Process Care practices like - VOC-CTQ-KPOV / KPIV Linkages KPIV / KPOV measurement tracking daily process care standards and Process control plans for effective daily work management.
• Monitor proficiency in testing and inter laboratory comparison to achieve accuracy in test reports.
• Monitor & review Daily Performance Indicators (DPIs) of AETs and DMTs across PBUs periodically to provide necessary support to excel in their performance and take necessary corrective & preventive actions for deviation.
• Plan & budget production consumption norms efficiencies and quality targets related to process care.
• Clear HDIN material make decision on NC material and help packing & sales coordinator to dispatch the material on schedule for shorter Cash Conversion Cycle.
• Identify & budget resources (equipment physical infrastructure material and people) for process care to support manufacturing initiatives services and offerings in line with business objectives.

Customer Centricity

• Meet and exceed internal & external customer expectations adhere with service level agreements (SLAs) and ensure implementation of action plans based on ICSI customer feedback & surveys.
• Ensure company-wide implementation of initiatives such as Mission Happiness Net Promoter Score CSI etc. to monitor customer satisfaction and undertake preventive & corrective measures to maximize satisfaction.
• Participate in organizational initiatives for Customer Relationship Management conduct periodic customer-supplier meets (both internal & external) and capture & report feedback for Voice of the Customer.
• Support in the formulation of SLAs of AETs & DMTs with other stakeholders and suggest any improvements.
• Ensure SLA formulation with all customers & suppliers and review for continuous improvements.
• Drive customer centricity and CVM (Customer Value Management) initiatives for internal and external customer delight.
• Instill customer centricity by developing and implementing structures / systems and processes for the following:

1. Understanding ever changing customer expectations
2. Understanding market dynamics and position product accordingly
3. Customer interface for both internal & external customers.

• Ensure product quality conformance to customer demand and support the team in identifying future needs of customer for long term customer retention.
• Partner with customers in understanding their product related issues / needs and modify or develop products to address them.
• Regularly visit and discuss with the raw material procurement team for quality and sustainability of supply.
• Train and educate the end user / processor on material specifications i.e. advise on material selection as per the application requirement for overall cost-benefit to the customer.

Process Capability & Quality Assurance

• Ensure formulation & implementation of SOPs and SMPs across Verticle.
• Create CoE Process Care & Quality Assurance roadmap for entire vertical and execute the roadmap initiatives with help from VST.
• Conduct periodic process & quality audits for AETs DMTs & CoE in PBUs develop & track the progress of corrective action plan and keep management informed throughout.
• Conduct process capability study (CP / CPK measurement) of all critical process & reduce variability and enhance process capability through improvement projects.
• Establish facilitate and conduct Gauge R&R for key process parameters and measurement systems to enable precise decision making.
• Provide impact analysis for any deviation in specification of input raw materials and facilitate corrective actions for mitigating the impact.
• Set-up a robust system for Quality parameter analysis trends monitoring and process control measures (SPC) for effective process care.
• Assist in achieving accurate dross analysis for copper percentage so that vendors dont challenge and company does not lose revenue through lower pricing.
• Develop systems & practices to evaluate the effectiveness of the deployed process control system for continuous improvement.
• Ensure achievement of targeted production with desired quality & highest productivity.
• Identify chronic issues based on major or minor deviations and recommend corrective actions for improvement to address process delays and other inefficiencies.

Value Creation & Process Leadership

• Prepare project charter & a detailed project management plan for every major initiative or value creation project and execute them accordingly.
• Drive the culture of problem solving and value creation to address performance gaps (SQCDPM) and customer issues (internal & external) through FI PI and Value creation projects.
• Review & monitor for effectiveness of FI PI Value Creation and other improvement projects in meeting their targets and future scope of improvement.
• Drive the following cost saving initiatives for reduction of production cost and de-bottlenecking:

1. Implement 3Rs- Repair Reuse & Recycle
2. Collaborate with unit and corporate procurement teams to develop alternate raw materials vendors etc.

• Lead the way to build Technology Upgradation Roadmap and address current and future technological needs of the business.
• Develop digital interventions by introducing modelling and simulation techniques in Plant process studies to take process care to next level of excellence / maturity.
• Calculate cost of poor quality and develop plans to reduce the cost of failure / rejection / rework / etc.
• Analyze & evaluate gaps in existing quality processes & practices and recommend actions in collaboration with PBUs to achieve process leadership.
• Develop system and processes to identify major initiatives & large value projects related to process leadership for each PBU.
• Conceptualize and create breakthrough projects as per roadmap / heat map for value creation drive process innovation through Value engineering and Value analysis and adopt latest technologies for achieving higher production volumes process capability and global standards of quality.
• Plan & strategize process and quality excellence practices implement effective process control strategies and standardize new / improved processes & practices.
• Undertake process & quality benchmarking initiatives study new technologies & introduce best practices to meet global standards of quality and exceed customer expectations.

Product & Process Development

• Control raw material & process quality to maintain the quality of finished goods and bring down cost of production

• Ensure execution of New Product & Process Development initiatives as per changing business & customer needs.

• Plan and execute process & quality improvement related CAPEX & Value creation projects in PBUs and ensure utilization of cash flows as per plan.
• Create a culture for systematic improvement of processes (FIT process mapping value stream mapping etc.) and identify areas for continuous improvement.
• Collaborate with PBUs for improvements in process engineering to reduce waste & cost of poor quality improve consumption norms etc.
• Partner the production teams in planning & budgeting with respect to CAPEX and inventory for the financial year and in achievement of cost saving through continuous process improvement with the help of R&D and new project implementation.
• Give Technical Approvals to purchase offers of Process Based Capex within defined timeline.
• Organize trials for development of a new product share reports & samples of profile dimension mechanical properties and chemical composition of the product with customers and ensure that after approval of the product samples marketing orders for its mass production.
• Drive process innovation through Value engineering i.e. - Alternate material alternate processes technological upgradation and other developmental projects to improve product & process quality.
• Explore conceptualize and propose digitalization projects for optimizing processes & significant improvement in product & process quality as per contemporary industry trends.

Capability Building & People Engagement

• Encourage & promote improvement activities / initiatives - 5S Kaizen FI PI and customer centricity through regular reward & recognition.
• Create learning architecture (curriculum courses and learning modules) using blended learning approach - a combination of education exposure and experience.
• Promote a culture of delegation & empowerment by giving employees autonomy to make decisions in their area of work by leveraging MPH Platform.
• Develop an internal trainer pool and facilitate training sessions for AET & DMT members to build their technical and behavioral capability.
• Ensure that a proper system for succession mapping & development is in place for all levels of organization with special focus on identifying and building succession pipeline for Business Critical Roles / Positions.
• Ensure that system is in place for skill / competency mapping for both technical & behavioral needs and skill inventory of AETs & DMTs have been maintained.
• Promote a culture of recognition appreciation and celebration to motivate & engage personnel not only for better results but for demonstrating right behaviors (ALERT & CASIO).
• Plan & ensure that AET members are trained in effective use of Process Care Frameworks (FMEA SPC tools & techniques Six Sigma TRIZ etc.)
• Build capacity (knowledge skills and attitude) of SMEs and keep up-to-date with latest process care and technology practices in manufacturing to become an authority in the field.
• Ensure participation in international and national seminar or conference to share knowledge increase networking opportunities and explore recent developments in the world of Copper.
• Partner with ABSTC HIC and other global R&D institutes / Innovation centers for improving & innovating products processes & technologies (advance knowledge sharing) and validation of developmental projects.
• Build capability of AET & DMT members for product & process understanding to be able to handle Daily work effectively.

HSE & Sustainability

• Develop sustainability roadmap in line with Plant / Group aspirations and conduct regular reviews to monitor its implementation.

• Institutionalize Enterprise Risk Management and Business Continuity Plan for PBU undertake sustainability risk assessment / heat map determine the level of risk by ensuring 100 % monitoring review & action on risk register and plan mitigation strategy.

• Drive strategic / large scale improvement initiatives under the guidance of Vertical Head and ensure all statutory requirements in Plant are met with focus on air and water pollution control for hazardous wastes and effluents.

• Identify health hazards that arise out of occupational design & human risk factors and implement programs to comply with statutory requirements & hazard mitigation.
• Embed a culture of safety to prioritize accident prevention at all levels of organization by following measures:
  1. Implement safety standards & procedures
  2. Develop safety mechanism / engineering controls (flange guarding conveyor guarding etc.)
  3. Facilitate safety related training to achieve zero harm
  4. Work in close co-ordination with all stakeholders to spread awareness.
• Ensure emergency handling readiness & training for crisis mitigation of all Cross Functional Teams across the Vertical through continuous recording of special events trip analysis failure analysis efficiency improvement benchmarking efficiency evaluation etc.

• Adopt digital practices that enable safe work environment (online alerts for PPE violation using AI for creating / refining / updating SOP for critical activities remote monitoring of confined spaces etc.)
• Develop ZLD (Zero Liquid Discharge) projects & collaborate to implement them and meet ZLD target for PBUs to control water pollution.
• Ensure ROHS (Restriction of hazardous substance) REACH and BIS testing through certified agencies and reporting for sale of FG in foreign markets.
• Maintain MSDS for all input raw materials impart MSDS awareness by displaying it and training AET & DMT members in its use for handling hazards associated with chemicals.
• Ensure that all changes are made through MOC system HAZOP / PSSR / HIRA is conducted for them and all identified hazards & unsafe behaviors are addressed using relevant matrix by collaborating with PBUs.
• Ensure compliance through regular reviews of all statutory regulatory & environmental norms and HIL standards for Occupational Health safety & environment to the satisfaction of all statutory bodies / auditors with focus on:

1. Environmental guidelines of CPCB (Central Pollution Control Board)
2. Hazardous waste management
3. Emission monitoring to control air & water pollution.