Production Manager - Power Transformers (132kv and above)

Job Purpose:

To lead and manage the complete Winding & Core Coil Assembly (CCA) production operations for power transformers up to 400 kV/500 MVA. The role ensures high-quality output, production efficiency, workforce planning, and strict adherence to safety, quality, and delivery standards.

Key Responsibilities:

1. Winding & CCA Operations Management

• Oversee daily production activities for LV/HV/Regulator winding and core-coil assembly.
• Ensure timely execution of production schedules aligned with project timelines.
• Optimize machine utilization, workforce allocation, and material availability.
• Monitor in-process quality checks during winding, brazing, lead connections, and assembly.
  

2. Quality & Compliance

• Ensure adherence to quality standards (IS/IEC), customer specifications, and internal QMS.
• Drive zero-defect philosophy through robust inspection processes and root-cause analysis.
• Collaborate closely with QA/QC teams for stage inspections and corrective actions.
  

3. Technical Expertise

• Strong knowledge of winding techniques (disc, helical, interleaved, multilayer, continuous).
• Understanding of insulation requirements, conductor selection, and mechanical strength design.
• Expertise in handling CCA, core stacking alignment, clamping, lead routing, and insulation clearances.
  

4. People & Team Management

• Lead a team of supervisors, technicians, and operators across winding and assembly areas.
• Coach and train teams on process improvements, machines, and best practices.
• Drive a culture of discipline, safety, and continuous improvement.
  

5. Production Planning & Control

• Coordinate with PPC, Design, SCM, and Testing teams to meet dispatch commitments.
• Track daily productivity, rejection, rework, and report variances with action plans.
• Implement lean manufacturing, 5S, Kaizen, and process automation where possible.
  

6. Safety, EHS & Machine Maintenance

• Ensure strict compliance with EHS guidelines in winding and CCA areas.
• Coordinate with maintenance teams for preventive maintenance of winding machines, hydraulic presses, ovens, etc.
  

Key Skills & Competencies:

• Strong technical knowledge of power transformer manufacturing (up to 400 kV/500 MVA).
• Expertise in Winding & CCA operations.
• Leadership & team-handling capabilities.
• Production planning, time management, and problem-solving skills.
• Knowledge of lean tools: 5S, Kaizen, TPM, continuous improvement.
• Quality-oriented mindset with strong analytical skills.
  

Educational & Experience Requirements:

• B.Tech / Diploma Electrical / Mechanical Engineering
• 7–15 years of experience in power transformer manufacturing.
• Hands-on experience in winding, CCA, insulation processes, and heavy engineering shop floors.