Head Foil Mill Operations

Masters India,  44 year old group, which is into Manufacturing, Healthcare, Hospitality and IT with an aggregate turnover of INR 1000+ crores. We are expanding rapidly and are, therefore, looking for leaders to help the company achieve its goals. We are expanding rapidly and are, therefore, looking for leaders to help company achieve its goals.

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