To lead, plan, and manage all aspects of setting up, operating, and continuously improving a manufacturing facility producing oil-filled submersible motors. This includes engineering design (including reverse engineering), plant layout, value engineering, production management, and in-process quality assurance to achieve targets in safety, cost, delivery, reliability, and product quality
ESSENTIAL DUTIES AND RESPONSIBILITIES
Facility Setup & Plant Layout
- Lead end-to-end establishment of the manufacturing facility: site selection input, utilities, infrastructure, power, water, HVAC, waste treatment, etc.
- Design plant layout for efficient flow of materials, components, subassemblies, final assembly, testing, packing, and shipping, ensuring safety, ergonomics, minimal material handling, and logical process flow.
- Select and establish workstations, cells, and lines; plan for future expansions.
- Plan for utilities and supporting facilities (oil storage/filling stations, cooling, testing labs, maintenance workshops).
Production Management & Process Control
- Plan, schedule, and oversee all manufacturing operations: stator winding, rotor fabrication, insulation, oil filling, rotor sealing, testing, assembly.
- Implement methods and metrics for productivity, yield, throughput, downtime, capacity utilization.
- Manage tooling, machinery, equipment procurement, installation, commissioning, preventive & breakdown maintenance.
- Oversee resource allocation: manpower, machines, materials, Time, shifts.
- Implement and sustain production planning & inventory systems (e.g., ERP / MRP).
Quality Assurance & In-Process Quality Control
- Define and monitor in-process quality checkpoints, inspections and tests (dimensional, electrical, insulation resistance, leakage, vibration, thermal performance, etc.).
- Ensure final product meets required performance, durability, compliance (standards / certifications) and reliability.
- Implement root cause analysis for rejects, nonconformances; corrective & preventive actions (CAPA).
- Ensure process stability using statistical process control (SPC), control charts, Poka-yoke, etc.
- Oversee calibration of instruments, testing lab, etc.
Advance Engineering & Reverse Engineering
- Oversight of engineering functions to design motor components, assemblies, tooling and fixtures.
- Lead reverse engineering initiatives where required: analyzing competitor or customer motors, remanufacturing or redesigning for performance, reliability, cost reduction.
- Ensure up-to-date engineering drawings, BOMs, tolerances, specifications, and change control in place.
- Interface with R&D / design engineers to ensure manufacturability (DFM), maintainability and robustness.
Value Engineering
- Identify cost reduction / value enhancement opportunities in materials, designs, processes while maintaining or improving performance, reliability, and safety.
- Evaluate alternative suppliers, substitute materials, optimize component designs.
- Apply techniques like life-cycle costing, cost-benefit analysis, benchmarking.
- Implement continuous improvement programs (Kaizen, Lean, etc.) to reduce scrap, rework, waste, cycle times.
Supply Chain & Materials Management
- Source raw materials, components, spares, including evaluation of vendors.
- Ensure material quality and timely deliveries to meet production schedules.
- Inventory management: raw material, WIP (work-in-progress), spare parts.
- Minimize holding costs and avoid material obsolescence.
Continuous Improvement & Technology Upgrades
- Deploy Lean, Six Sigma, 5S, SMED, value stream mapping, etc.
- Monitor technological trends (e.g. improved insulation, oil formulations, motor efficiency) and assess adoption.
- Use data analytics, production metrics, root cause problem solving to improve yield & reduce cost.
- Benchmark vs industry best practices.
Safety, Environment, Health & Regulatory Compliance
- Ensure plant operations comply with safety, environmental, health regulations.
- Implement PPE, safe handling of oil, chemicals, electrical hazards, fire safety.
- Maintain environmental permits, oil spill control, waste oil treatment/disposal.
- Drive safety culture including training, audits, hazard identification and mitigation.
Budgeting, Cost Control & Financial Performance
- Prepare capital expenditure (CapEx) plans (machinery, tooling, test equipment, facility infrastructure).
- Prepare operational budget, monitor vs actuals: labor, materials, utilities, maintenance.
- Monitor cost per unit, cost overruns, implement cost saving measures.
- Manage supplier costs, material consumption, yield losses.
Leadership & Human Resources
- Recruit, train, develop technical and shop floor teams: engineers, technicians, operators.
- Set clear performance goals: safety, quality, productivity, cost.
- Drive culture of continuous improvement, accountability.
- Oversee shift supervision, cross-department coordination (engineering, quality, maintenance, procurement, R&D).
