Manufacturing Head (Plant Operatons)

Experience into precision engineering and manufacturing company engaged in the production of high-precision machined components for the automotive and defence sectors.

Role & responsibilities

Position Overview

The Manufacturing Head will be responsible for the overall management of manufacturing operations, engineering, production planning, quality, maintenance, process improvements, and New Product Development (NPD). The incumbent will lead a team of approximately 100 employees comprising engineers, supervisors, operators, and support staff, ensuring world-class manufacturing practices while meeting customer expectations on Quality, Cost, Delivery, Safety, and Morale.

This role requires a hands-on leader with strong technical expertise in precision machining, excellent people management skills, commercial acumen, and a passion for continuous improvement.

Key Responsibilities

Manufacturing Operations

• Lead and manage end-to-end plant operations to achieve production, quality, delivery, and cost objectives.
• Ensure optimum utilization of manpower, machinery, tooling, and production resources.
• Drive daily production planning and execution to achieve customer delivery schedules.
• Monitor plant KPIs and implement corrective actions wherever necessary.

Production Planning & Control

• Coordinate with Planning, Purchase, Stores, and Sales to ensure uninterrupted production.
• Review production schedules and optimize capacity utilization.
• Minimize production bottlenecks and improve throughput.

Process Engineering & New Product Development

• Lead process planning, feasibility studies, APQP activities, PFMEA, Control Plans, and process validation for new products.
• Develop manufacturing processes for new components with optimum productivity and quality.
• Support product costing, cycle time estimation, tooling selection, and process optimization.
• Coordinate with customers during product development and trial stages.

Precision Machining Excellence

• Drive operational excellence across CNC Turning Centres, VMCs, HMCs, Grinding, Honing, Broaching, and special-purpose machines.
• Improve Overall Equipment Effectiveness (OEE), machine utilization, productivity, and process capability.
• Optimize tooling life, cutting parameters, cycle times, and setup reduction initiatives.

Quality & Compliance

• Ensure compliance with IATF 16949, ISO 9001, customer-specific requirements, and statutory regulations.
• Drive Zero Defect initiatives through SPC, MSA, PPAP, FMEA, Root Cause Analysis, and CAPA.
• Support customer audits and certification audits.
• Build a strong quality culture across all manufacturing functions.

Continuous Improvement

• Lead Lean Manufacturing, Kaizen, 5S, TPM, Poka-Yoke, Visual Management, and Waste Elimination initiatives.
• Identify cost reduction opportunities through process improvements and value engineering.
• Improve productivity, quality, and manufacturing efficiency on a continuous basis.

Inventory & Supply Chain Coordination

• Work closely with Stores and Purchase to maintain optimum inventory levels.
• Control WIP, raw material, consumables, tooling, and finished goods inventory.
• Monitor inventory turnover and reduce manufacturing losses.

Vendor Development

• Develop and evaluate strategic vendors for machining, tooling, heat treatment, plating, and outsourced processes.
• Participate in make-versus-buy decisions based on commercial and operational considerations.
• Ensure supplier quality, delivery performance, and cost competitiveness.

Maintenance & Asset Management

• Ensure preventive and predictive maintenance of all manufacturing equipment.
• Improve machine availability and minimize breakdown losses.
• Plan capital expenditure for new machinery, technology upgrades, and automation projects.

Cost Management

• Prepare manufacturing budgets and monitor operational expenditure.
• Drive manufacturing cost reduction through process improvements, productivity enhancement, and resource optimization.
• Monitor labour efficiency, machine utilization, tooling costs, and overall manufacturing profitability.

Team Leadership

• Lead, mentor, and develop engineers, supervisors, and shop-floor personnel.
• Build a culture of accountability, discipline, safety, teamwork, and continuous learning.
• Identify training needs and develop technical competencies across manufacturing teams.
• Conduct regular performance reviews and succession planning.

Health, Safety & Environment

• Ensure strict compliance with safety policies and statutory requirements.
• Promote safe working practices and maintain a zero-accident culture.
• Support environmental sustainability initiatives and regulatory compliance.

Key Performance Indicators (KPIs)

• Production achievement against plan
• On-Time Delivery (OTD)
• Overall Equipment Effectiveness (OEE)
• First Pass Yield (FPY)
• Customer PPM and internal rejection levels
• Manufacturing cost reduction
• Inventory turnover and WIP control
• Tooling cost optimization
• Machine utilization
• Productivity improvement
• New Product Development milestones
• Employee productivity and engagement
• Safety performance and statutory compliance

Required Qualifications

Education

• Diploma (DME) or Bachelor's Degree (B.E./B.Tech.) in Mechanical, Production, Manufacturing, or Industrial Engineering.

Experience

• 12 -15+ years of progressive experience in precision machining or automotive component manufacturing.
• Minimum 5 years in a senior manufacturing leadership role managing plant operations.

Preferred candidate profile

Technical Competencies

• Strong expertise in CNC machining, VMC/HMC operations, grinding, honing, tooling, fixtures, gauges, and process engineering.
• Hands-on experience in APQP, PPAP, FMEA, SPC, MSA, Control Plans, and IATF 16949 Core Tools.
• Good understanding of Lean Manufacturing, TPM, Kaizen, SMED, and Six Sigma concepts.
• Knowledge of ERP/MRP systems and manufacturing MIS.
• Working knowledge of CAD/CAM software will be an added advantage.

Leadership Competencies

• Proven ability to lead and motivate a workforce of 50100 employees.
• Strong analytical, problem-solving, and decision-making skills.
• Excellent planning, coordination, and execution capabilities.
• Strong communication and stakeholder management skills.

Commercial awareness with the ability to balance operational and financial objective