Head – Foil Mill Operations

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

Qualifications

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