This position plans for all shutdowns, preventive maintenance, condition-based monitoring for supporting sections like Operation, Maintenance, Quality (In House Quality & Customer Quality) & Packing. Optimizing common resource consumptions, common spare availability, and getting benefitted with inventory management, item procurement plan, and cost efficiency.
Role & Responsibilities:
Strategic Leadership & Plant Performance
- Drive operational excellence by optimizing plant performance to meet Production, Quality, Cost, Delivery, and Safety (PQCDS) targets while upholding stringent quality commitments.
- Spearhead greenfield project execution in the automotive sector, focusing on value addition in extruded sections, component machining line planning, execution, and establishment.
- Formulate and implement lean manufacturing, Six Sigma, and Kaizen principles to improve operational efficiency and minimize waste.
- Oversee budget forecasting and financial planning in coordination with Operations, Maintenance, and Quality teams to ensure cost optimization and resource efficiency.
Production & Process Optimization
- Lead the execution of end-to-end production strategies for CNC, VMC, chamfering, and conventional machines, ensuring high throughput and precision manufacturing.
- Develop and implement production planning systems to optimize workload distribution, minimize downtime, and enhance overall equipment effectiveness (OEE).
- Oversee the procurement, maintenance, and utilization of cutting-edge machinery, tools, and consumables to ensure seamless production.
- Drive new product development (NPD) by integrating customer requirements, component drawing studies, jig and fixture planning, and trial runs.
- Collaborate with design, inspection, maintenance, and supply chain teams to achieve on-time delivery, zero-defect production, and high customer satisfaction.
Technology & Innovation
- Leverage advanced CNC machining technologies, including FANUC, MAZAK, and SIEMENS-controlled systems, to enhance precision and operational agility.
- Lead automation and digital transformation initiatives to streamline production workflows and integrate data-driven decision-making.
- Implement predictive and preventive maintenance strategies to minimize unplanned downtime and ensure machinery reliability.
Quality Assurance & Compliance
- Establish and maintain ISO/TS 16949, FMEA, and PPAP compliance, ensuring the highest manufacturing and safety standards.
- Lead root cause analysis (RCA) and corrective action plans to address quality issues and continuously improve processes.
- Drive the adoption of process control methodologies and defect prevention systems, reducing in-house and customer rejections.
Reliability & Maintenance Management
- Develop and execute preventive maintenance schedules, condition-based monitoring, and equipment history tracking to enhance reliability.
- Ensure minimal plant breakdowns by optimizing common resource consumption, spare parts availability, and procurement strategies.
- Manage contractor operations through CLMS platforms, ensuring compliance with safety and quality standards.
Supply Chain & Packing Optimization
- Establish and standardize component packing systems based on customer specifications to eliminate process rejections.
- Implement single-piece flow packing concepts to improve efficiency and reduce material waste.
- Oversee inventory planning and control, ensuring optimal stock levels for raw materials, consumables, and spare parts.
People & Performance Management
- Build and mentor a high-performing team, fostering goal setting, process ownership, and continuous skill development.
- Lead cross-functional collaboration with internal stakeholders, including Operations, Quality, and Maintenance, to drive seamless production.
- Champion a safety-first culture, ensuring compliance with product, human, and equipment safety standards.
Preferred Candidate Profile:
- Bachelor's degree in Mechanical, Production, or Industrial Engineering (Masters preferred).
- 20+ years of experience in machine shop operations, with expertise in CNC machining.
- Strong knowledge of automotive component machining and value-added extrusion processes.
- Hands-on experience in FANUC, MAZAK, and SIEMENS CNC programming.
- Proven ability to lead teams, drive process improvements, and optimize production.
- Experience with lean manufacturing, TPM, and OEE improvement strategies.
- Knowledge of safety standards, quality control processes, and maintenance best practices.
- Excellent problem-solving, leadership, and stakeholder management skills.
Employment Type: Full Time, Permanent
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