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…