Senior Production Manager

Plant Head / Director Operations

Manufacturing Plant - LALRU (AMBALA)

To plan, organize, monitor and control all production activities of the Foundry and CNC Machine Shop, ensuring delivery of quality products on time, optimum utilization of manpower and machines, adherence to safety standards, and continuous improvement in productivity and cost.

• Execute daily, weekly and monthly production plans.
• Ensure achievement of production targets as per customer schedules.
• Monitor production output and machine utilization.
• Coordinate between Foundry, Machine Shop, Quality, Maintenance and Stores.
• Ensure uninterrupted production flow.

• Supervise all foundry activities including:
• Melting
• Moulding
• Core Shop
• Pouring
• Fettling
• Shot Blasting
• Heat Treatment (if applicable)
• Monitor metal yield and recovery.
• Reduce rejection and rework.
• Ensure process parameters are maintained.

• Plan machining activities on:
• CNC Turning Centres
• Vertical Turning Lathes (VTL)
• Vertical Machining Centres (VMC)
• Horizontal Machining Centres (HMC)
• Monitor machine utilization and Overall Equipment Effectiveness (OEE).
• Ensure machining schedules meet dispatch commitments.
• Coordinate tooling and fixture availability.

• Monitor:
• Daily production
• Machine downtime
• Cycle time
• Productivity
• Labour efficiency
• Conduct daily production meetings.
• Review pending orders and priorities.

• Ensure production conforms to approved drawings and specifications.
• Work closely with the Quality Department to reduce:
• Rejections
• Customer complaints
• Internal defects
• Implement corrective and preventive actions.

• Allocate manpower effectively.
• Supervise supervisors and operators.
• Train production employees.
• Maintain discipline on the shop floor.
• Evaluate employee performance.

• Coordinate preventive maintenance schedules.
• Report machine breakdowns immediately.
• Minimize production losses due to equipment failure.
• Ensure proper upkeep of production equipment.

• Coordinate with Stores for raw material availability.
• Monitor:
• WIP (Work in Progress)
• Consumables
• Tooling
• Inserts
• Fixtures
• Minimize material wastage.

• Improve production efficiency.
• Reduce:
• Scrap
• Rework
• Power consumption
• Tool consumption
• Production costs
• Suggest cost-saving initiatives.

• Implement Lean Manufacturing practices.
• Promote 5S implementation.
• Improve productivity through Kaizen activities.
• Standardize work procedures.
• Reduce cycle time.

• Ensure compliance with safety procedures.
• Conduct safety toolbox talks.
• Maintain proper use of PPE.
• Ensure statutory compliance related to production operations.
• Maintain housekeeping standards.

• Daily Production Report
• Prepare and submit:
• Shift Production Report
• Machine Utilization Report
• Rejection Report
• OEE Report
• Downtime Report
• Productivity Report
• Manpower Report
• Dispatch Readiness Report

• Production Target Achievement (%)
• On-Time Delivery (OTD)
• Machine Utilization (%)
• Overall Equipment Effectiveness (OEE)
• Productivity per Employee
• CNC Machine Efficiency
• Foundry Yield (%)
• Casting Rejection (%)
• Machining Rejection (%)
• Scrap Reduction
• Rework Reduction
• Labour Productivity
• Tool Consumption
• Customer Complaints
• Safety Incidents
• Inventory Accuracy

• Diploma or B.Tech./B.E. in Mechanical, Production, Metallurgical or Industrial Engineering.
• Additional certifications in Lean Manufacturing, Six Sigma or TPM are desirable.
  

• 10–15 years of experience in a foundry and CNC machining environment.
• At least 5 years in a managerial or supervisory role.
• Experience in manufacturing precision machined castings for OEMs is preferred.
  

• Production Planning & Control (PPC)
• Foundry process knowledge
• CNC machining operations
• Process optimization
• OEE monitoring
• Lean Manufacturing
• TPM
• Root Cause Analysis
• CAPA implementation
• Reading engineering drawings
• Knowledge of measuring instruments and quality standards
• ERP/MRP systems
• Microsoft Excel and reporting tools

• Strong leadership and team management
• Decision-making ability
• Problem-solving and analytical skills
• Excellent communication and coordination
• Time management
• Customer-focused approach
• Ability to work under pressure
• Continuous improvement mindset

The Production Manager is authorized to:

• Allocate manpower and production resources.
• Prioritize production schedules.
• Stop production in case of major quality or safety concerns.
• Recommend process improvements and corrective actions.
• Coordinate with Quality, Maintenance, Stores, PPC and HR to achieve production objectives.

This JD is suitable for an integrated manufacturing facility with both a foundry and CNC machine shop, such as Vishwas Overseas, and can be incorporated into your HR manual or recruitment process.