About the role
Role Objective
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
1. 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
2. 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
3. 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
4. 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
5. 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
6. 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
7. 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
8. 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
Good to Have
Experience with high-speed foil mills and thin gauges
Exposure to Lean / TPM / Six Sigma
Familiarity with ERP / MES systems
Experience in export-quality foil standards