AGM - Operations
1. Operations and Production Management
- Strategic Planning: Develop and execute the plants operational strategy to align with overall business objectives.
- Production Targets: Own and ensure the achievement of daily, weekly, and monthly production, quality, and delivery targets.
- Process Optimization: Drive efficiency and productivity by monitoring and optimizing all stamping, welding, assembly, and post-processing operations.
- OEE Improvement: Lead initiatives to maximize Overall Equipment Effectiveness (OEE) for stamping presses and associated machinery.
- Supply Chain: Oversee inventory management, logistics, and raw material procurement to ensure optimal flow and minimal disruption.
2. Quality and Continuous Improvement
- Quality Standards: Establish, maintain, and enforce stringent quality control systems (e.g., ISO, IATF/TS standards) to achieve a zero-defect culture.
- Problem Solving: Lead Root Cause Analysis (RCA) and implement robust Corrective and Preventive Actions (CAPA) for all process and quality issues (wrinkles, cracks, springback, etc.).
- Lean & Six Sigma: Champion Lean Manufacturing and Six Sigma methodologies (e.g., Kaizen, 5S) to reduce waste, control costs, and improve manufacturing processes.
3. Financial and Cost Control
- Budget Management: Prepare, manage, and monitor the annual plant budget, controlling costs related to manpower, utilities, maintenance, and scrap.
- Cost Reduction: Initiate and drive cost reduction projects through process re-engineering, material utilization improvement, and efficiency gains.
- CAPEX: Manage capital expenditure projects for new equipment, tooling, or plant expansion, ensuring a strong Return on Investment (ROI).
4. Leadership and People Management
- Team Leadership: Lead, mentor, and develop a high-performing management team and all plant employees.
- Culture & Safety: Foster a positive, engaging, and performance-driven work culture with an unwavering commitment to safety (Zero Accident Policy) and statutory compliance.
- Industrial Relations: Maintain harmonious industrial relations and ensure effective communication across all levels of the organization.
5. Maintenance and Tool Room
- Equipment Upkeep: Oversee the maintenance function to ensure proactive preventive and predictive maintenance (TPM) of all stamping presses, dies, and auxiliary equipment.
- Tooling Strategy: Provide strategic direction for the in-house tool room, focusing on die design, try-out, maintenance, and life cycle management.
Required Qualifications and Skills
Qualifications:
- Education: Bachelors degree in Mechanical Engineering, Production Engineering, Industrial Engineering, or a related field. MBA or Postgraduate in Operations Management is a strong advantage.
- Experience: Minimum of 10-15 years of progressive experience in manufacturing, with at least 5 years in a senior leadership role (Plant Manager/Head) in a high-volume Sheet Metal Stamping/Press Shop environment, preferably in the automotive or heavy engineering sector.
Project Engineer/ Sr. Engineer
I. Stamping Process & Tooling
- Die and Tooling Management: Oversee the technical coordination of die design, build, try-out, and qualification for new and modified progressive, transfer, and tandem dies.
- Formability & Feasibility: Lead Design for Manufacturing (DFM) reviews with Product Engineering, conducting technical analysis and forming simulations (e.g., AutoForm) to ensure new designs are stampable and meet Geometric Dimensioning & Tolerancing (GD&T) requirements.
- Process Optimization: Define, standardize, and maintain critical stamping process parameters, including tonnage, speed, cushion pressure, and lubrication systems, for blanking, drawing, trimming, and piercing operations.
- Troubleshooting: Provide expert, hands-on support for complex stamping defects (cracks, wrinkles, springback, dimensional issues), leading Root Cause Analysis (RCA) and implementing permanent corrective actions at the die or press level.
II. Operations Excellence & Continuous Improvement
- Lean Implementation: Champion and drive Lean Manufacturing principles specific to stamping, such as rapid SMED (Single-Minute Exchange of Dies), scrap reduction, and layout optimization for material flow.
- Equipment & Capacity: Manage the specification, justification (ROI), procurement, installation, and commissioning of new stamping presses, coil feed lines, and automation systems. Perform regular capacity planning and debottlenecking studies.
- Documentation: Own and maintain all manufacturing technical documents for the stamping area, including Process Flow Diagrams, Control Plans, PFMEAs, and detailed Standard Work/Operating Instructions (SWI/SOPs).
- Cost Reduction: Initiate and manage projects to reduce variable costs, focusing on material utilization, scrap rate reduction, and improvement of die life/tooling maintenance frequency.
III. Leadership & Management
- Team Leadership: Lead, mentor, and develop a team of Stamping Engineers, Die Designers, and Process Technicians.
- Safety & Compliance: Ensure all stamping operations and equipment comply with strict internal and external safety standards, including die setup, guarding, and lockout/tagout (LOTO) procedures.
- Cross-Functional Interface: Coordinate actively with Production, Quality, Maintenance, and Tool & Die departments to ensure smooth operation, timely die repairs, and immediate quality issue resolution.
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Required Qualifications & Experience
- Education: Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, or equivalent. A Master's degree is a plus.
- Experience: 5 to 10 years of progressive experience in sheet metal stamping and forming processes.
- Stamping Technical Expertise: Non-negotiable deep technical knowledge of Die Design (Progressive/Transfer), high-speed press operation, and the metallurgy of stamped materials (e.g., High Strength Steels - AHSS, Aluminum).
- Software Proficiency: Experience with CAD software (e.g., CATIA, NX, SolidWorks) and forming simulation software (e.g., AutoForm, PAM-STAMP) is required.
- Quality Systems: Strong understanding of APQP, PPAP, SPC, and MSA principles, particularly in an automotive (IATF 16949) or similar quality-driven environment.
Asst Manager/ Deputy Manager - Production
1. Production Planning and Execution
- Target Achievement: Own and ensure the consistent achievement of daily, weekly, and monthly production volume, efficiency, and delivery targets as defined by Production Planning & Control (PPC).
- Resource Allocation: Effectively manage and allocate production resources, including manpower, stamping presses, auxiliary equipment, and materials, to meet the schedule efficiently.
- Flow Management: Oversee the entire production sequence, from coil feeding and stamping to welding, assembly, and final packaging, identifying and eliminating bottlenecks.
- Downtime Minimization: Proactively work with Maintenance and Tool Room teams to minimize unplanned press downtime, improve Mean Time Between Failures (MTBF), and expedite effective Mean Time To Repair (MTTR).
2. Operational Efficiency and Cost Control
- OEE Improvement: Drive continuous improvement initiatives focused on maximizing Overall Equipment Effectiveness (OEE) for all critical stamping presses and production lines.
- Lean Manufacturing: Champion the implementation and sustained practice of Lean principles (e.g., 5S, Standard Work, Visual Management) to reduce waste (scrap, waiting time, movement).
- Cost Control: Closely monitor and control operational expenses, specifically focusing on reduction of scrap/rework costs, optimal utilization of raw material (coils), and labor efficiency.
- Process Optimization: Continuously analyze production processes to identify and implement improvements that increase throughput and reduce cycle time without compromising part quality.
3. Quality Assurance
- Zero Defect Focus: Work with the Quality team to establish and enforce strict process control parameters to ensure a "First Time Right" approach, minimizing internal and external defects (PPM).
- Defect Resolution: Lead the Production team in the immediate identification, containment, and initial investigation of stamping defects (cracks, wrinkles, dimensional variance), collaborating with Engineering/Tooling on permanent corrective actions.
- Standard Work: Ensure all operators and supervisors strictly adhere to approved Standard Operating Procedures (SOPs) and Quality Control Plans.
4. Team Leadership and Safety
- People Management: Lead, mentor, and motivate a large team of Production Supervisors, Press Operators, Die Setters, and Assemblers across multiple shifts.
- Skills Development: Identify training needs and organize training programs for stamping technology, safety procedures (LOTO), and quality checks to enhance team competency.
- Safety First: Ensure an absolute commitment to safety in all stamping operations. Enforce all HSE policies, LOTO procedures, and machine guarding regulations to maintain a Zero Accident environment.
Qualifications:
- Education: Bachelors degree in Mechanical Engineering, Production Engineering, or a related technical field.
- Experience: Minimum of 8-12 years of progressive experience in a manufacturing environment, with at least 4 years in a senior managerial role (Production Manager or equivalent) within a Sheet Metal Stamping/Press Shop environment.
Essential Skills & Knowledge:
- Stamping Process Mastery: Deep, hands-on knowledge of high-tonnage stamping presses (hydraulic and mechanical), progressive dies, transfer dies, and forming fundamentals (e.g., blanking, drawing, springback).
- Operational Metrics: Proven ability to manage a production floor based on metrics like OEE, scrap rate, PPH (Parts Per Hour), and productivity indices.
- People Leadership: Exceptional leadership, coaching, and conflict resolution skills for managing a large, multi-shift workforce.
- Systems: Strong working knowledge of ERP/MRP systems and the ability to drive quality management systems (e.g., IATF 16949).
Assistant Manager - Weld Shop
Core Responsibilities
I. Operations & Production Management
- Target Attainment: Ensure daily, weekly, and monthly production schedules and output targets are achieved by maximizing equipment uptime and labor efficiency.
- Workforce Supervision: Provide direct supervision and leadership to shift supervisors, welding leads, technicians, and operators across all shifts. Manage work assignments, shift schedules, and staffing levels.
- Process Flow: Monitor and optimize the flow of material, work-in-progress (WIP), and finished goods through the weld shop to prevent bottlenecks.
- Troubleshooting: Lead the immediate response to production stoppages, equipment faults, and complex welding defects. Coordinate quick repairs with the Maintenance department.
- Consumables Management: Oversee the inventory and proper usage of welding consumables (wire, gas, tips, electrodes) to minimize waste and ensure quality.
II. Technical Excellence & Quality Control
- Process Control: Ensure strict adherence to approved Welding Procedure Specifications (WPS), work instructions, and quality standards (e.g., AWS, ISO, or industry-specific).
- Welder Certification: Manage the welder qualification and certification program, ensuring all personnel are certified for the processes they perform (e.g., GMAW, GTAW, Resistance Welding).
- Quality Assurance: Work closely with the Quality team to monitor in-process checks, minimize weld defects (porosity, lack of fusion, distortion), and implement corrective actions based on inspection results.
- Fixture & Tooling: Oversee the setup, maintenance, and periodic inspection of welding jigs, fixtures, and robotic tooling to maintain dimensional accuracy.
III. Safety & Continuous Improvement
- Safety Compliance: Enforce rigorous safety protocols specific to welding environments (fire prevention, fume extraction, PPE, and machine guarding). Conduct routine safety audits and hazard identification.
- Continuous Improvement: Champion and implement Lean Manufacturing principles specific to welding, such as reducing changeover time, minimizing rework, and optimizing cell layouts.
- Equipment Maintenance: Coordinate with the Maintenance department to schedule and execute Preventative Maintenance (PM) on welding robots, power sources, positioners, and ventilation systems.
- Training: Provide technical coaching and cross-training for welders and operators on new products, updated procedures, and advanced welding techniques.
Required Qualifications & Experience
- Education: Diploma or Bachelor's degree in Welding Engineering Technology, Mechanical Engineering, Manufacturing Engineering, or a related field. Certification as a Certified Welding Inspector (CWI) or equivalent is highly preferred.
- Experience: 5 to 10 years of experience in high-volume, structural, or precision welding/fabrication, with at least [Insert Number] year in a supervisory or managerial role.
- Technical Skills:
- Expert knowledge of multiple welding processes (GMAW, GTAW, Resistance Welding, or Laser Welding) and metallurgy of common materials.
- Hands-on experience with welding automation and robotics (programming, teaching, and troubleshooting).
- Strong ability to read and interpret complex engineering drawings, specifications, and welding symbols.
Key Skills & Competencies
- Technical Leadership: Proven ability to lead, mentor, and motivate a team of skilled welders and technicians.
- Quality Orientation: Deep commitment to achieving and maintaining high-quality weld joints and structural integrity.
- Problem-Solving: Excellent analytical and systematic troubleshooting skills for production and process issues.
- Safety Focus: Uncompromising dedication to maintaining a safe work environment in a hazardous shop setting.
Tool Room Manager
Key Responsibilities
Tooling Management & Maintenance
- Preventive Maintenance (PM): Develop, implement, and manage a robust Preventive Maintenance schedule for all press tools to ensure maximum availability and life.
- Repairs & Modifications: Oversee the timely and high-quality repair, troubleshooting, and modification of all production tooling, jigs, and fixtures.
- New Tooling: Manage the manufacturing, commissioning, and testing of new press dies and tooling, ensuring they meet design specifications and production requirements.
- Tool Records: Maintain accurate and detailed records of all tool history, including maintenance logs, repair costs, and performance data.
- Inventory & Spares: Manage the inventory of tool steel, spare parts, and consumables, ensuring critical items are always stocked to support continuous production.
Production Support & Quality
- Minimize Downtime: Work closely with the Press Shop and Maintenance teams to quickly resolve tooling-related issues and significantly reduce press downtime.
- Tool Performance: Monitor and analyze tooling performance metrics (e.g., hits per regrind, part quality) and implement continuous improvement actions.
- Technical Support: Provide expert technical advice on tool design, material selection (e.g., tool steel, heat treatment), and press-related process optimization.
- Quality Compliance: Ensure all repaired and manufactured tooling meets strict quality standards and specifications (e.g., dimensional accuracy, surface finish).
Leadership & Administration
- Team Supervision: Lead, mentor, and manage the Tool Room team, including scheduling, performance reviews, and technical training.
- Budget Management: Prepare and manage the Tool Room's operational budget, including spending on materials, equipment, and outsourcing.
- Safety & Housekeeping: Implement and enforce all safety protocols (LOTO, machine guarding, PPE) and maintain high standards of 5S and housekeeping in the tool room.
- Capital Investment: Identify needs and make recommendations for the purchase of new tool room machinery (e.g., CNC, grinding machines) and technologies.
Qualifications and Skills
Required Qualifications
- Bachelor's degree in Mechanical/Tool Engineering, or a Diploma in Tool and Die Making with extensive relevant experience.
- 5-8 years of experience in Tool Room operations, with a minimum of 3 years in a managerial or supervisory role, preferably in a high-volume Press Shop/Sheet Metal environment.
- In-depth, hands-on knowledge of progressive, compound, and single-stage press tools.
- Strong understanding of machining processes (Milling, Lathe, Grinding, EDM) and CNC programming.
Key Skills
- Technical Expertise: Superior ability to read and interpret complex mechanical/die drawings, GD&T (Geometric Dimensioning and Tolerancing).
- Leadership: Proven ability to manage, train, and motivate a team of skilled tradespeople.
- Problem-Solving: Excellent root cause analysis (RCA) and troubleshooting skills for die-related defects (e.g., burrs, cracks, splits).
- Communication: Strong verbal and written communication skills for internal reporting and coordinating with external vendors.
- Software: Proficiency in inventory management systems (e.g., SAP, ERP) and basic CAD software is a plus.
Asst Manager/ Manager - Maintenance
1. Maintenance Strategy and Management
- Asset Reliability: Develop, implement, and lead comprehensive maintenance strategies, including Total Productive Maintenance (TPM), focusing on preventive, predictive, and condition-based maintenance for all hydraulic and mechanical stamping presses, coil feed lines, and automation systems.
- Downtime Reduction: Implement effective failure analysis (e.g., Root Cause Analysis - RCA) to identify and eliminate chronic machine breakdowns, aiming to maximize press uptime and achieve ambitious MTBF (Mean Time Between Failures) and minimize MTTR (Mean Time To Repair) targets.
- Spare Parts & Budget: Manage the maintenance budget and critical spare parts inventory, optimizing costs without compromising equipment reliability or delivery schedules.
- Technical Compliance: Ensure all machinery and maintenance practices adhere to safety standards (e.g., LOTO) and regulatory requirements.
2. Production Engineering & Process Optimization
- Process Stability: Oversee the technical engineering support for the production floor, ensuring optimal process parameters (e.g., Blank Holder Force, cushion pressure, velocity) are maintained for all running jobs to achieve maximum yield and quality.
- Productivity Improvement: Drive engineering projects aimed at enhancing productivity, reducing cycle times, and improving material utilization through automation, fixture design, and process sequencing adjustments.
- Process Validation: Validate and approve all new stamping processes and equipment installations (FAT/SAT), ensuring they meet capacity, quality, and maintainability requirements.
- Tooling Collaboration: Work closely with the Tool Room and R&D to provide technical feedback on die performance, identifying opportunities for engineering modifications that improve robustness and die life.
3. Capital Projects (CAPEX) and Technology
- Investment Justification: Lead the technical evaluation and justification of new capital investments, including press upgrades, new press installations, and automation equipment, ensuring a strong Return on Investment (ROI).
- Technology Integration: Research and implement new manufacturing technologies (e.g., sensing technology for condition monitoring, industry 4.0 applications) to enhance operational transparency and control.
4. Leadership and Cross-Functional Collaboration
- Team Leadership: Lead, mentor, and develop the Maintenance, Mechanical, and Electrical Engineering teams, fostering a culture of technical excellence and collaboration.
- Safety Integration: Ensure all engineering and maintenance activities strictly follow safety protocols and contribute actively to the plant's Zero Accident goals.
- Interface: Serve as the key technical interface between Production, Quality, and R&D to resolve complex process and equipment-related quality issues swiftly.
Required Qualifications and Skills
Qualifications:
- Education: Bachelors degree in Mechanical Engineering, Electrical Engineering, or a related technical discipline. A Master's degree or advanced certification in Maintenance Management is an asset.
- Experience: Minimum of 12-15 years of progressive experience in an engineering or maintenance function, with at least 5 years in a combined or senior leadership role within a Sheet Metal Stamping, Forging, or heavy equipment manufacturing environment.
Essential Skills & Knowledge:
- Press Technology: Expert technical knowledge of the design, mechanics, hydraulics, and controls of high-tonnage mechanical and hydraulic stamping presses.
- Reliability Engineering: Proven proficiency in maintenance methodologies (TPM, RCM) and reliability improvement metrics (MTBF, MTTR, OEE).
- Process Optimization: Strong background in applying Lean principles and engineering analysis to optimize manufacturing processes.
- System Integration: Experience managing CAPEX projects and integrating new equipment controls with existing plant systems (PLCs, SCADA).
