DGM - Operations

Role & responsibilities

Production scheduling

Assess existing demands and constraints for production; Finalize the production volumes in coordination Production planning. Drill down the weekly plan for production and make daily plan. Prepare weekly shift rosters for operators and ensure availability of the required operators in each line. Decide on the Shift schedules based on the order portfolio. Monitor and fine tune daily production planning based on OTDM requirements. Modify the daily production plan in case of customer requirement.

Achieve Production Targets

Monitor production performance on a daily basis. Continuously review the volume achievement, OTDM, OTDC2, ULO. Analyse reasons for performance / non performance along manager and during SIM. Monitor the production process, MDR rates, report the deviations to Dy. Manager production and department head and receive inputs from them to correct the situation. Continually look for opportunities and methods for improving performance. Communicate effectively in operator SIM, the issues, corrective action plan to the operators and motivate the team to implement the same. Monitor performance of the operators and correct deviations if any; Coach / counsel the operators to follow instructions, exhibit disciplined behavior and complete work efficiently on time; Tactfully handle situations of indiscipline and deviant behaviors; Inform the higher officials and HR and take action to arrest such occurrences;

Monitoring Production and improving continually

Monitor Target vs actual pn daily / shift basis. Monitor down time on shift basis. Track defect occurrences and perform root cause analysis to curtail the same. Participate in SIM to discuss issues with cross functional teams and resolve. Record SIM minutes accurately and discuss issues, corrective action status, plan for the day, plan vs actuals on a daily basis and update the minutes. Conduct operators SIM and guide them to track and record production related data effectively.

Implementation of SPS, ISO systems

Understand in detail the SPS applicable to production; Work with the operators to implement the same. Implement 5 S, Safety, Visual management, material handling system as per SPS guidelines; Understand and follow ISO systems including ISO 9001 – 2000, ISO 140001, OHSAS; Implement the SOPs and work instructions as per ISO guidelines

Monitor and control Rejections / Booking Scrap

By the end of the shift match physical vs system stock and arrive at rejection quantities on a shift basis. Book the scrap in SAP. Perform root cause analysis along with the supervisors and operators and work towards reducing the rate of rejection

Monitoring and guiding line setters

Guide line setters to monitor and collect scrap on an hourly basis; Guide them to track down time, plan vs actual on an hourly basis. Train them to accurately enter details in SIM reports and also give apt reasons for prevalence of such conditions; Develop the habit of clearing all the white poles (whether WIP / rework) before the end of the shift and account for the same.

Safety

Implement safety systems and procedures meticulously; Stop production if unsafe act / condition is noticed; resume only after necessary actions are taken to prevent unsafe working conditions. Create awareness on safety amongst operators. Motivate them to adhere to safety standards.

House Keeping

Implement 5S house keeping system at the shop-floor. Deploy 5 S activities, Provide training to operators on 5 S and ensure adherence to 5 S procedures. Based on audit findings take action to improve house keeping at shop floor.

Training and Development.

Identify the training needs of the operators and provide them multi skill training in coordination with Human resources and methods team. Ensure the timely execution of the training programs. Conduct on the job training for operators in order to develop their skill in various operations.