Lead - Production Engineering

Unique Job Role:

Function:

Reporting to:

Business:

Business description:

External Interfaces - Internal Interfaces

Vendors
Technology partners Technical consultants Machine manufacturers Overseas partners Production departments ¢ Service departments¢ Safety officerJob Requirements EducationB.E/B.TechRelevant Experience & Language17 to 23 years of exp. in relevant industryLanguages known Tamil, English Behavioural Skills¢ Customer orientation¢ Leadership & Team Management¢ Self-motivated & Proactive thinking¢ Adaptability¢ Networking¢ Conflict Management¢ Problem solving & Decision making¢ Collaborative mind-set & Co-creation¢ Empathy & Resilience¢ Communication Skills¢ Attention to detail¢ Analytical & Logical thinkingKnowledge¢ Engineering Product Design¢ Tool Design ¢ Tool Manufacturing¢ Manufacturing Processes like Press, Machining, Polishing, Plating & Assembly¢ Production Planning & Control¢ Quality Management System¢ Cost Management¢ Operational Excellence¢ New Product Management¢ Tools & Techniques like Six Sigma, DFMEA, DOE, etc.,¢ Strategic Planning¢ Technical Skills & Industry Knowledge¢ Safety & Compliance

Role detailsProcess ContributionProcess OutcomePerformance Measure

A. Production Management

1. Ensuring the identified capabilities are Proved, Piloted, Scaled and Matured at each production shops
2. Capacity working for next 2 to 3 years horizon
3. Decision on building capacity at INH / Sub-con / Import
4. CAPEX / Revenue budgeting
5. CAPEX Proposal Review
6. Ensuring Effective Org. structure in place
7. Manpower requirement proposal to HR
8. Driving OEE at Shop floors

• Capability Chart
• Capacity Mapping
• CAPEX Budget
• CAPEX Proposal
• Manpower ratio Sign-off
• Capacity Ratio INH : Sub : IMP
• Production Performance Trend
• OEE Analysis & Action
• Capability Index
• Volume Alignment
• IRR
• Per Capita Output
• OEE

1. Quality Management
2. Define and document quality standards for each stage of production
3. Ensure compliance with relevant quality management systems and certifications
4. Implement quality control (QC) procedures for Input materials, in-process and finished products.
5. Foster a culture of quality awareness and continuous improvement among staff
6. Ensuring use tools such as process mapping, control charts, and statistical process control (SPC) to ensure process consistency and capability
7. Establish a system for identifying, documenting, and addressing non-conformities
8. Implement corrective and preventive actions (CAPA) to resolve issues and prevent recurrence
9. Regularly track and analyse Quality metrics to assess performance and drive improvements
10. Encourage continuous improvement initiatives, such as Lean, Six Sigma, and Kaizen, to enhance quality and efficiency
11. Implement measures to address customer complaints and improve overall satisfaction
12. Implement advanced technologies, such as automated inspection systems and real-time data analytics, to enhance quality control
13. Conduct regular risk assessments to proactively address potential quality issues

• Quality Standard
• Quality Performance Report
• Quality Analysis & CAPA Report
• In-Process control Chart
• IMS document
• Kaizen Sheet
• Customer Satisfaction Report
• FTA
• COQ
• Main Assy. Return (MAR)
• IMS Certification
• Customer Satisfaction Index

1. Cost Management
2. Develop and implement an annual budget (Material & OH) for production operations
3. Allocate resources effectively across various departments and processes
4. Regularly review cost reports to track actual spending against the budget for each production area
5. Identify and control direct and indirect production expenses
6. Analyse each production shop and vendor operation to identify inefficiencies and areas for improvement
7. Cost benchmarking with competition across value chain
8. Implement Lean, Six Sigma, and other process improvement methodologies to reduce costs
9. Optimize inventory levels to balance costs with production needs
10. Implement Just-In-Time (JIT) inventory systems to reduce holding costs
11. Optimize workforce deployment and productivity
12. Conduct regular cost analysis to identify trends, variances, and opportunities for cost reduction
13. Foster a culture of continuous improvement focused on cost reduction and efficiency across all production shops and vendor operations

• Annual OH & Material Budget
• Budget Analysis & Justification
• Wow Saving Plan Vs Actual
• SCE outcome analysis
• Inventory Plan Vs Actual
• Cost Benchmarking
• Cost trend (OH & Mat.) Analysis and initiatives
• SCE Vs Actual
• Analysis Budget Vs Actual
• Cost Variance Analysis
• OH, Mat. & Case Cost CAGR
• Case Cost competitiveness
• Per capita output
• OH Absorption
• Inventory Turns

1. Delivery Management ( New Product & Regular )
2. Develop production schedule cut-off of each components and stages that aligns with case delivery deadlines
3. Ensure all production shops (Press, Machining, Polishing, Plating, Bought outs & Assembly ) are synchronized to meet delivery targets
4. Implement strategies to handle peak periods and minimize bottlenecks
5. Track production progress in real-time using manufacturing execution systems (MES)
6. Identify and address any deviations from the production schedule promptly
7. Conduct regular reviews of delivery performance against targets
8. Analyse and optimize production processes to reduce lead times
9. Implement lean manufacturing principles to streamline operations
10. Define and monitor key performance indicators (KPIs) related to delivery performance, such as on-time delivery rate, lead time, and order accuracy
11. Use data analytics to identify trends and areas for improvement
12. Identify potential risks that could impact delivery schedules, such as equipment failures or supply chain disruptions
13. Gather feedback from customers and stakeholders to identify areas for improvement

• Lead time based Delivery Cut-off
• Delivery Performance Trend
• Delivery Plan Vs Actual
• Shortfall analysis & CAPA
• Buffer Stock plan Vs Actual
• Lead Time Benchmarking
• Delivery Alignment (New & Regular)
• Volume Alignment
• Lead time Agility
• Customer Satisfaction

1. People Management
2. Assess current workforce capacity and skills
3. Forecast future staffing needs based on production plans and growth projections
4. Define job roles and responsibilities clearly
5. Develop and implement training programs to enhance technical and soft skills
6. Encourage continuous learning and professional development
7. Set clear performance expectations and goals for team members
8. Conduct regular performance reviews and provide constructive feedback
9. Recognize and reward employee achievements and contributions
10. Promote teamwork and collaboration across different production shops and departments
11. Encourage cross-functional projects to enhance cooperation and innovation
12. Implement effective conflict resolution strategies to maintain a harmonious work environment
13. Provide opportunities for career advancement and skill development
14. Create a succession plan to ensure continuity in key roles
15. Foster a leadership culture that aligns with the company's values and goals

• Skill / Competency Matrix / FCM
• Individual Development Program
• Goal Setting
• Quarterly / Half Yearly / Annual Review & Feedback (PMS)
• Training & Development Plan
• Learning Documentation
• R&R
• Succession planning
• Org. Structure
• GPTW Manager Score
• Career progression
• Current Proficiency level.

1. Safety & 5S Management
2. Promoting safety & 5S as a culture for everyone on the production floor
3. Ensure that all machinery, tools, and processes are evaluated for safety risks
4. Develop and implement strategies to eliminate or control identified hazards
5. Ensure that comprehensive safety SOPs are developed, documented, and adhered by all employees
6. Driving 5S principles at Shop floors & Offices
7. Track key performance indicators (KPIs) related to 5S and safety

• HIRA
• TSHMS Assessment Report
• 5S Management Audit Report
• Zero Incidents / Accidents
• 100% TSHMS Score
• 5S Certification