Process Improvement Head- Iron Foundry

Job Title: Process Improvement Head

Experience Required: Minimum 20 Years

Qualification: Diploma / B.E. (Mechanical / Production / Industrial Engineering preferred)

Location: Coimbatore

Annual Budget: Up to ₹20 Lakhs

Role Objective:

To lead continuous improvement, process optimization, and cost reduction initiatives across the Machine Shop and related production functions, ensuring productivity enhancement, quality consistency, and operational excellence in alignment with organizational goals.

Key Responsibilities:

Production Planning & Coordination

1. Prepare daily machine loading plans based on the production schedule received from the Planning Department.
2. Communicate and coordinate the plan with Shift In charges and Tool Room for seamless execution.
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4. Collaborate with Vendor Development for subcontract processes and capacity management.
5. Support NPD in new product trials and pilot sample production.
6. Coordinate with Foundry Production for timely availability of castings.

Process Improvement & Productivity Enhancement

1. Monitor machine productivity and identify improvement areas; report to Head – Manufacturing with corrective actions.
2. Drive initiatives for cycle time reduction, tool cost optimization, and process efficiency improvement through Kaizen and Lean practices.
3. Analyze rejection data and implement process-level corrective and preventive actions.
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5. Coordinate with the Maintenance team for preventive maintenance and uptime improvement.
6. Implement automation projects to enhance productivity and optimize manpower deployment.

Cost & Resource Management

1. Ensure cost control across all manufacturing processes, including variable and fixed expenses.
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3. Initiate cost-reduction projects and track performance against defined KPIs.
4. Ensure smooth flow of parts to Finished Goods as per Marketing and dispatch requirements.

Safety, Quality & Environment

1. Conduct Aspect & Impact and HIRA (Hazard Identification & Risk Assessment) analyses periodically to ensure compliance and safety.
2. Promote EMS (ISO 14001:2015) awareness and adherence among Supervisors and Operators.
3. Implement safety control measures and ensure strict PPE compliance.
4. Conduct EMP (Environmental Management Program) and RRP (Resource Recovery Program) to maintain environmental sustainability.
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6. Oversee waste management and disposal processes in line with statutory and company norms.

Desired Competencies:

• Proven expertise in process improvement, Lean Manufacturing, and Six Sigma methodologies.
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• Strong analytical and problem-solving skills with hands-on exposure to machining operations.
• Demonstrated ability to lead cross-functional improvement projects.
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• Excellent leadership, communication, and stakeholder management skills.
• Sound understanding of safety, environmental, and quality management systems (ISO 14001, ISO 9001).