Senior Manager - Continuous Cast Copper Rod

Adani Natural Resources · India

The Senior Manager – CCR will be responsible for safe, reliable and efficient operation of the Continuous Cast Rod plant, covering copper rod production, process control, quality adherence, productivity improvement and shift coordination. The role will ensure achievement of production targets, process stability, equipment utilization, product quality, energy efficiency and operational discipline in line with business, safety and customer requirements.

The incumbent is expected to bring strong hands-on understanding of CCR operations, copper rod casting and rolling process, furnace operation, casting wheel, rolling mill, cooling system, pickling / surface quality, process parameters, defect analysis, maintenance coordination and shop-floor governance to deliver consistent rod quality, higher plant availability and continuous improvement.

A. CCR Production Operations & Target Delivery

• Lead day-to-day CCR production operations to achieve planned copper rod output, quality and dispatch readiness.
• Ensure smooth operation of shaft furnace / holding furnace, casting system, rolling mill, cooling, coiling and handling areas.
• Monitor production plan versus actual performance, identify deviations and drive corrective actions with shift teams.
• Optimize plant throughput, yield, availability and operating discipline while minimizing process interruptions and rework.
• Ensure effective shift handover, daily production review, manpower deployment and shop-floor execution governance.

B. Safety, Compliance & Shop-Floor Discipline

• Ensure adherence to safety standards, SOPs, PTW requirements, LOTO, PPE compliance and safe operating practices in CCR operations.
• Drive hazard identification, near-miss reporting, unsafe condition closure and safety engagement with operators and contract workforce.
• Maintain operational discipline through checklist compliance, logbook accuracy, housekeeping, 5S and process control documentation.
• Ensure statutory, environmental and quality system compliance applicable to CCR production operations.
• Build a safety-first operating culture across shifts through training, audits and visible shop-floor leadership.

C. Process Control, Quality & Defect Reduction

• Maintain critical process parameters for molten copper temperature, oxygen level, casting speed, rolling conditions, cooling and surface finish.
• Work with quality, laboratory and process teams to ensure copper rod meets required specifications for diameter, conductivity, elongation, surface quality and coil condition.
• Analyze process deviations, rod breaks, surface defects, dimensional variation, cracks, scale formation and other quality issues.
• Drive root-cause analysis and corrective / preventive actions for recurring process and quality failures.
• Support process trials, standard parameter setting and improvement projects for stable CCR operations.

D. Equipment Reliability, Maintenance Coordination & Utility Interface

• Coordinate closely with mechanical, electrical, instrumentation and utility teams for equipment health, breakdown analysis and preventive maintenance planning.
• Monitor critical equipment including furnace, casting wheel, rolling stands, shear, coiler, cooling system, pumps, burners and material handling systems.
• Support planned shutdown execution, equipment readiness checks, start-up preparedness and post-maintenance trial stabilization.
• Identify reliability concerns impacting production, quality, energy consumption and safety performance.
• Ensure timely closure of process-related maintenance observations and operational improvement actions.

E. Continuous Improvement, Cost & Team Development

• Drive improvement initiatives for productivity, yield, energy efficiency, consumable consumption, downtime reduction and quality cost reduction.
• Use production data, process trends, defect analysis and equipment performance inputs to identify improvement opportunities.
• Develop SOPs, OPLs, training modules and skill-building plans for operators, technicians and shift personnel.
• Support digitalization of production monitoring through dashboards, shift MIS, process analytics and automated reporting.
• Build a high-performance production team focused on safety, quality, reliability, accountability and continuous improvement.

Education and Experience Required

• B.E./B.Tech in Metallurgy, Mechanical, Electrical, Chemical, Production or Industrial Engineering.
• 10–15 years of experience in copper rod / CCR operations, non-ferrous metals production, casting and rolling, process control, production planning or plant operations in large manufacturing setups.
• Minimum 4–6 years of direct exposure to CCR plant operations, copper rod quality, furnace / casting / rolling process, shift management, troubleshooting and maintenance coordination.