Senior Manager- CCR

Senior Manager- CCR

Responsibilities

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.

Qualifications

Education Qualification:

• B.E./B.Tech in Metallurgy, Mechanical, Electrical, Chemical, Production or Industrial Engineering.

• Additional qualification in Operations Management, Process Engineering, Quality Management or Manufacturing Excellence will be preferred.

   

Work Experience (Range of years):

• 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.