Operations Head - Manufacturing

Description:

Job Summary:

The Operations Head is responsible for end-to-end management of plant operations, including production planning, resource utilization, safety, quality, cost control, and process optimization across Press Shop, Weld Shop, Robotic Production, Assembly, and Quality functions.

The role ensures smooth, efficient, and compliant operations while meeting customer schedules, productivity targets, and cost objectives.

Key Responsibilities:

Production & Operations Management:

- Plan and allocate resources in line with customer schedules and production targets.

- Conduct regular meetings with HODs to review production performance, targets, and new process implementations.

- Ensure uninterrupted production and smooth functioning of assembly and manufacturing processes across three shifts.

- Oversee Press Shop (Heavy Presses), Weld Shop, Robotic Production, Assembly, and Quality operations.

- Ensure effective line balancing, lead time reduction, and productivity improvement.

Process Improvement & System Implementation:

- Drive continuous improvement initiatives including 5S, Kaizen, mistake-proofing (Poka-Yoke), VA/VE, and cost-saving projects.

- Analyze rejection, rework, and quality issues; define countermeasures and ensure execution with the team.

- Implement and sustain TPM activities (JH, PM, QM, KK).

- Lead feasibility studies for new processes, automation, and robotic solutions.

- Implement auto-handling systems using gantry and positioner solutions.

- Manage robot handling, mastering, axis teaching, calibration, and robotic line setup.

Quality & Customer Management:

- Ensure zero customer complaints through strong quality systems and proactive issue resolution.

- Support Quality teams for customer issues, internal handling rejections (IHR), and corrective actions.

- Coordinate with Development and Quality teams for new business, new line setups, and QAV clearance from RFQ to SOP.

- Interact with customers for daily and monthly supply planning and performance reviews.

Cost & Resource Control:

- Monitor and manage consumables and spare parts cost with respect to sales.

- Optimize utilization of manpower, machines, and materials to improve operational efficiency.

- Oversee Capex planning and implementation aligned with business needs.

Safety & Compliance:

- Promote safety awareness across the plant and implement initiatives to improve workplace safety.

- Ensure compliance with safety standards, procedures, and statutory requirements.

Project & Plant Setup:

- Provide technical and commercial support for new projects, from concept to customer supply.

- Lead new line installations, layout design, and plant setup from greenfield stage to SOP.

Reporting & Review:

- Review monthly MRM data across departments and prepare action plans to improve plant efficiency.

- Submit monthly operational performance and MRM analysis reports to top management.

Skills & Competencies:

- Strong leadership and team management capabilities

- Excellent technical knowledge of manufacturing, assembly, automation, and robotics

- Strong analytical, problem-solving, and decision-making skills

- Effective communication and stakeholder management skills

- High level of personal organization and time management

- Ability to work under pressure in a fast-paced manufacturing environment

- Collaborative mindset with cross-functional coordination capabilities