Executive - Forging & Rolling

Role & responsibilities

Position Purpose

To support the day-to-day operations of the Cold Forging shop, ensuring smooth production, adherence to quality and safety standards, optimum machine utilization, and achievement of production targets. The role will involve hands-on shop-floor coordination and process monitoring across cold forging operations.

Key Responsibilities

1. Production & Shop-Floor Operations

• Execute daily production plans for cold forging as per defined production schedules.
• Monitor machine-wise production, productivity, rejection and downtime.
• Ensure optimum utilization of machines, manpower, tools and dies.
• Monitor and control cycle time, setup time and machine efficiency.
• Ensure adherence to standard operating procedures and defined process parameters.
• Coordinate with maintenance, quality, tooling and PPC teams for smooth production.

2. Cold Forging Process

• Handle and monitor cold forging operations involving multi-station / multi-die cold headers, bolt makers, nut formers or similar equipment.
• Understand basic cold forging processes such as heading, upsetting, extrusion, piercing, trimming and forming.
• Monitor tool/die condition and coordinate for timely replacement or correction.
• Identify process abnormalities and support troubleshooting of forging-related issues.
• Ensure proper line clearance and changeover activities as per SOP.

3. Quality & Process Control

• Ensure production is carried out as per approved process parameters and quality standards.
• Monitor common forging defects such as cracks, laps, folds, underfill, dimensional variation and improper forming.
• Coordinate with Quality for first-piece approval and in-process inspection.
• Support root-cause analysis and implementation of corrective/preventive actions.
• Maintain process and production records accurately.

4. Productivity & Continuous Improvement

• Identify opportunities for improving OEE, productivity, yield and machine utilization.
• Support initiatives for reduction of rejection, tool consumption, setup time and material wastage.
• Participate in Kaizen, 5S, TPM, Lean Manufacturing and continuous improvement initiatives.
• Analyze production data and highlight deviations and improvement opportunities.

5. Safety & Compliance

• Ensure strict adherence to all EHS and shop-floor safety practices.
• Ensure PPE compliance and safe operating practices.
• Report unsafe conditions, incidents and near misses promptly.
• Maintain workplace discipline and 5S standards.

6. MIS & Reporting

• Prepare daily production and productivity reports.

• Track key parameters including:

• Production quantity

• Rejection / rejection %

• OEE

• Downtime

• Tool life

• Setup/changeover time

• Material utilization

• Escalate production constraints and critical issues to the reporting manager.