Production Manager

Job Responsibilities:

this role combines technical expertise with management and leadership skills to drive productivity, control costs, and manage personnel.

1. Die Casting
2. Vibro/Surface Finishing
3. Tapping
4. Plating i.e. Trivalent Blue/Chrome/Nickel or Powder Coating
5. Assembly
6. Plastic Injection Moulding
7. Eccentric Power Press
8. Sealing Foams
9. Vulcanization

Resource Management

• Estimating and budgeting for resource requirements, including materials, labour, and equipment.
• Overseeing the selection, ordering, and purchasing of necessary materials and equipment.
• Managing and allocating personnel, materials, and equipment effectively.

Production Process & Management

• Scheduling:

  Planning and monitoring production schedules on a daily, weekly, and monthly basis to meet customer demands and delivery deadlines.

• Optimization:

  Continuously reviewing and improving production processes to enhance productivity, reduce waste, and optimize cycle times. This includes implementing lean manufacturing techniques such as Kaizen, 5S, and Total Productive Maintenance (TPM).

• Troubleshooting:

  Expertly handling and resolving technical issues and defects that arise during the production processes, such as porosity, shrinkage, and cold shuts etc.

• Equipment oversight:

  Managing the proper use and maintenance of machines, melting furnaces, robotics, and auxiliary equipment.

Team and Personnel Leadership

• Supervision and training:

  Leading and managing a team of engineers, supervisors, and operators. This includes providing training to enhance skill levels and monitoring team performance and discipline.

• Performance evaluation:

  Conducting regular performance reviews and providing coaching to production associates.

• Resource allocation:

  Scheduling production staff to ensure adequate coverage and optimal use of manpower resources.

• Hiring:

  Participating in the hiring process for new employees within the production department.

Quality Assurance

• Standards enforcement:

  Ensuring that products meet both internal quality norms and external customer standards.

• Minimizing defects:

  Implementing root cause analysis to minimize rejections and ensure defect-free castings.

• Document review:

  Approving and reviewing process control documents such as Process Failure Mode and Effects Analysis (PFMEA) and control plans.

• Collaboration:

  Working closely with the Quality Assurance (QA) and Quality Control (QC) teams to uphold quality standards and address customer complaints promptly.

Equipment and maintenance management

• Preventive

  maintenance:

  Ensuring that preventive and breakdown maintenance schedules for all machinery and tooling are followed effectively to maximize uptime.

• Tooling lifecycle:

  Proactively managing the lifespan of dies and tools, and planning for their refurbishment or replacement.

• Troubleshooting

  equipment:

  Working with maintenance teams to troubleshoot mechanical, hydraulic, pneumatic, and automation issues related to equipments.

Safety and compliance

• Safety promotion:

  Promoting a strong culture of safety and housekeeping within the facility.

• Regulation compliance:

  Ensuring all operations adhere to safety, health, and environmental regulations.

• Risk assessment:

  Conducting regular safety audits and risk assessments in die casting areas.

Coordination and reporting

• Interdepartmental collaboration:

  Acting as a liaison between the production team and other departments, including planning, maintenance, quality, and supply chain.

• Performance reporting:

  Generating and reviewing production reports, such as Manufacturing Information Systems (MIS) and downtime analysis, and communicating performance to senior management.

• Cross-functional meetings:

  Participating in meetings and audits with cross-functional teams to align production with broader business objectives.

Production & Efficiency KPIs

• Overall Equipment Effectiveness (OEE):

  A comprehensive metric measuring the overall productive time of equipment, combining availability, performance, and quality. Machines downtime and operational status.

• Production Output/Volume:

  The total number of units produced over a specific period.

• Throughput:

  The rate at which a production system produces units per unit of time.

• Manufacturing Cycle Time:

  The average time it takes to complete a product from start to finish.

• Capacity Utilization:

  Measures how much of a facility's production capacity is being used.

• Cost Per Unit (CPU):

  The total cost to produce one item.

• Scrap Rate:

  The percentage of materials or products that are discarded due to defects.

• First Pass Yield (FPY):

  The percentage of units produced that pass quality inspections the first time without needing rework.

• Customer Complaints:

  The number of complaints received, indicating product quality or reliability issues.

• On-Time Delivery (OTD):

  The percentage of orders delivered to customers by the promised date.

• Production Schedule Compliance:

  Measures how well the production team adheres to the planned production schedule.