Job Title:
Group
Company
Industry:
Location:
Reporting to:
Experience:
Qualification:
Purpose of the Role
The primary purpose is to achieve budgeted production volumes of high-quality products and the set target of On-Time In-Full (OTIF). This is accomplished by establishing robust processes and systems in Operations with a focus on Safety, Health, and Environment (SHE), Quality, Productivity, Cost Control, Operational Efficiency, and Employee Welfare, ensuring alignment with the Business requirements and Business Plan.
Critical Aspects & Requirements (Specialized Experience)
The role requires specific, profound experience in the precision steel tube making industry:
Experience in Precision Steel Tube Making:
A minimum of 15 to 20 years of knowledge and practice.Troubleshooting Skills:
Expertise in troubleshooting Precision Steel Tube Mill Operations, specifically concerning:- Knowledge and practice of HF Induction Welding Fundamental Principles.
- Roll Tooling Function & Tooling Maintenance for Precision Steel Tube Mills.
- ID Scarfing Tooling arrangements for Precision Steel Tube Mills.
- Autonomous Maintenance & Planned Maintenance Programs for Tube Mills.
- Tube Mill Alignment & Inspection Techniques.
- Precision Tube Mill Set-up techniques & Setting qualification Procedures, including Weld Forge line Micro.
Product Expertise:
Knowledge and practice of Precision Steel Tube Product Specification & Special requirements for different categories of applications.Process Qualification:
Knowledge and practice of Tube Mill Process qualification & NDT flaw detection techniques and methods.New Product Development (NPD):
Exposure to NPD with assessment of Tube Mill considerations.Advanced Steel Grades:
Knowledge & practice of manufacturing techniques for Precision Steel Tubes using High-Strength Low-Alloy (HSLA) & Advanced High-Strength Steel (AHSS) grades.Abnormality Identification:
Skills for identification of abnormalities in Equipment / Tooling (Rolls).Analytical Ability:
The capability to relate operational parameters for enhanced process control and the stratification of data for a better understanding of process results.
Role & Responsibilities / Key Accountabilities
I. Production, Quality, and Operational Excellence
Volume & Delivery:
Achieve budgeted volumes of Production and 85% OTIF (On-Time In-Full) to the customers. Accountable for Production Volume and On-Time Delivery (OTD).Quality Management:
Achieve High Quality Products (100% FTR).- Develop and monitor the adherence of Quality Standards and Parameters.
- Eliminate the top three defects: weld crack, surface defects, and dimensional defects at in-house, aiming for Zero Customer Complaints / Zero PPM at the Customer's end.
- Accountable for In Plant Rejections and Customer Rejections & Complaints.
- Drive a TQM culture.
Efficiency & Resources:
Utilize existing resources effectively , focusing on planning, machine effectiveness, and man productivity.- Improve Overall Equipment Efficiency (OEE).
- Manage resources (Machines & Material) effectively.
- Ensure effective utilization of Tube Mills and control Work-In-Progress (WIP) through coordination with Planning.
II. Cost Management and Profitability
Cost Control:
Reduce fixed costs (man-power) and variable costs (fuel and yield) through short-term and long-term projects.- Control expenditure by monitoring and executing planned actions to achieve budgeted manufacturing cost and improve profitability.
- Accountable for Material Yield and Productivity , Specific Energy Consumption (ensuring within budgeted level) , and Consumable & Tool cost control.
- Generate and implement CAPEX & SREP Proposals.
III. SHE, TQM, and Employee Development
Safety & Compliance (SHE):
Achieve 100% SHE Performance.- Ensure compliance with all statutory requirements and 100% adherence to ISO / TS, SHE & ERP.
- Generate & Implement Improvements for Safety & Ergonomics of Operators.
- Accountable for Safety.
TQM and Operational Excellence:
Take a key role in the implementation of TQM and driving Total Employee Involvement (TEI).- Drive TQM culture and utilize TQM / TPM Tools and Techniques.
- Generate & Implement Operational Excellence, Lean & TPM Improvements and Kaizens.
- Monitor and review progress of Kaizen, SGAs, and CFTs.
- Accountable for Operational Excellence, Lean & Total Productive Maintenance (TPM) initiatives.
Maintenance:
Accountable for Maintenance of equipment.- Coordinate with Maintenance for periodical Preventive Maintenance, up-keeping of Equipment condition & Spares procurement and Maintenance.
- Coordinate with Tool Room for Roll Maintenance, Abnormality correction and improvements.
People Management & Development:
Assess and enhance the capabilities of the Workforce (Associates) through functional expertise training (classroom and floor).- Training topics include safety in materials handling, product application, autonomous maintenance, tooling maintenance, and skill rotation.
- Develop subordinates for improving their capabilities & Knowledge.
- Ensure effective management of Manpower.
- Maintain discipline and morale among employees at the shop floor.
- Handle employee grievances and provide counselling to Managers, Engineers, and Employees.
Inter-functional Coordination:
Connect leaders from SHE, Planning, Materials, Quality, Maintenance, Sales & Marketing, TQM, NPD and HR in different forums to drive initiatives for manufacturing process excellence.
Specific Accountabilities
This position is accountable to the Plant Head and for the Tube Mills and ERW Finishing operations in the following specific areas:
Production Volume
Achievement of Planned volume on a Month wise / Annual basis.
Material & Cost
Achievement of budgeted yield on a Month wise / Annual basis.
Ensuring Energy consumption is within the budgeted level.
Consumable & Tool cost control.
Operational Efficiency
Improvement of Overall Equipment Efficiency (OEE).
Delivery
Ensuring On-Time Delivery (OTD) for ERW major customers.
Quality
Reduction of In-plant Rejections - ERW.
Reduction of Customer Rejection & Complaints.
New Product
Rolling of New Product Development (NPD) sizes as per Plan.
Continuous Improvement
Generation & Implementation of Operational Excellence, Lean & Total Productive Maintenance (TPM) Improvements and Kaizens.
Generation & Implementation of Improvements for Safety & Ergonomics of Operators.
Maintenance & Projects
Co-ordination with Maintenance for periodical Preventive Maintenance, up keeping of Equipment condition & Spares procurement and Maintenance.
Identification, Generation & Implementation of CAPEX & SREP Proposals.
Co-ordination with Tool Room for Roll Maintenance, Abnormality correction and improvements.
Planning & Inventory
Co-ordination with Planning for effective utilization of Tube Mills, and for Controlling Work-In-Progress (WIP).
People Management
Ensuring discipline and morale among Employees at Shop Floor.
Developing Sub-ordinates for improving their capabilities & Knowledge.
Required Knowledge, Skills, and Functional Competencies
Knowledge
- OHSAS & ISO14001
- Quality Management Systems
- Maintenance System
- Business Plan
- Manufacturing Technology
- Product Application
- Inventory Control
- TQM / TPM Tools and Techniques
- Budgeting Process
- Recovery & Contingency Planning
- Operational Excellence and Lean practices
Skills
- Attention to details
- Critical Thinking (Troubleshooting)
- Problem Solving
- Decision Making
- Cost Conscious
- People Development
- Innovation
- Customer Centricity
- Escalation and Reporting
- Analytical ability to stratify data
- Ability to maintain discipline
Functional Competencies
- Production Management
- Quality Management
- Cost Management
- Inventory Management
- SHE & Compliance Management
- Training & Development
- TQM Promotion & Management
