Production Head

Head of Production Foundry (Automotive Castings)

Role Summary

entire production operations of the foundry

Key Responsibilities

1. Production Planning & Control

• Prepare and execute daily, weekly, and monthly production plans aligned with customer schedules.
• Coordinate with Sales, Planning, and Supply Chain for raw material and dispatch alignment.
• Monitor melting, molding, core making, fettling, and machining processes to ensure balanced flow and minimal bottlenecks.
• Track

  OEE (Overall Equipment Effectiveness)

  and productivity metrics.

2. Process Optimization & Efficiency

• Drive

  Lean Manufacturing, Kaizen, TPM, and 5S

  initiatives.
• Identify and eliminate process wastes (scrap, rework, downtime, excessive energy consumption).
• Ensure optimal utilization of manpower, machines, and materials.
• Implement automation and digitalization projects (

  Industry 4.0

  ) for process improvement.

3. Quality Assurance

• Collaborate with the Quality Head to ensure defect-free castings.
• Maintain process capability (

  Cp, Cpk

  ) and adherence to control plans and work instructions.
• Lead cause analysis (8D, Fishbone, Pareto) for internal and customer complaints.
• Ensure metallurgical quality: composition, microstructure, and mechanical properties.

4. Maintenance & Equipment Reliability

• Coordinate with Maintenance to maximize equipment uptime.
• Approve and review preventive and predictive maintenance schedules.
• Ensure quick resolution of breakdowns and furnace-related issues.

5. Safety, Health & Environment (SHE)

• Enforce foundry safety protocols, PPE usage, and safe handling of molten metal.
• Conduct safety audits, risk assessments, and accident investigations.
• Ensure environmental compliance (emissions, sand reclamation, waste disposal).

6. Manpower Management

• Supervise and mentor production engineers, shift in-charges, and operators.
• Define KPIs and conduct performance reviews for production staff.
• Drive training and skill development in foundry practices, equipment operation, and safety.
• Manage manpower deployment, shift planning, and overtime control.

7. Cost Control

• Monitor production costs per ton/casting, yield losses, and energy utilization.
• Initiate cost reduction projects through process improvements or sourcing changes.
• Prepare and control departmental budgets for consumables, maintenance, and utilities.

8. Customer & Cross-functional Coordination

• Collaborate with Quality, R&D, and Customer Service for new part developments and audits.
• Support

  PPAP, trial castings, and product validation

  for new models.
• Participate in customer audits and technical reviews.

9. Compliance & Documentation

• Ensure compliance with

  IATF 16949, ISO 14001, ISO 45001

  and other standards.
• Maintain production records, process logs, and performance dashboards.
• Lead internal and external audits related to production systems.

Authority

The Head of Production has the authority to:

• Approve production schedules and manpower deployment.
• Authorize machine shutdowns/startups in coordination with Maintenance.
• Approve consumption of materials, energy, and tools within budget.
• Sanction overtime and shift adjustments.
• Recommend hiring, promotion, or disciplinary actions for production personnel.
• Approve capital expenditures related to production equipment (within delegated limits).
• Stop production if safety or quality is compromised.

Reporting Structure

• Reports to:

  Plant Head / General Manager – Operations / Managing Director

• Direct Reports:

• Production Managers / Shift Engineers
• Process Engineers
• Supervisors / Operators

• Interfaces with:

  Quality, Maintenance, SCM, HR, Safety, R&D, and Finance departments

Key Performance Indicators (KPIs)

Category

KPI Metrics

Productivity

Tons per man-hour, OEE, yield (%)

Quality

Rejection %, customer complaints, Cp/Cpk

Cost

Cost per ton, energy per ton, consumables usage

Qualifications

• Education:

  Diploma or Bachelor’s in Mechanical/Electrical Engineering.

• Experience:

  20+ years in foundry or heavy engineering industries.

Application Details

recruitment@kiswok.com, avijit.dey@kiswok.com, soma.mukherjee@kiswok.com.

Note: