Function Head - Operations

The Function Head - Operations will be responsible for framing and executing operational strategies for all products within the Fine Blanking Business Unit (MFPD division). The role involves directing and controlling end-to-end manufacturing operations, robust production planning, warehouse quality, cost management, and quality management systems (QMS) across all regions (domestic and exports). The primary goal is to drive PQCDSM (Productivity, Quality, Cost, Delivery, Safety, Morale) to ensure business profitability, free cash flow, and exceptional customer satisfaction.

Key Responsibilities & Performance Metrics (PQCDSM)

1. Manufacturing Strategy & Operational Excellence (20% of Time)

• Develop, plan, and execute manufacturing strategies to enhance plant performance and improve Overall Equipment Effectiveness (OEE).

• Target production output metrics: Achieve 6,000 strokes per shift per press in Plant 1 and 8,000 strokes per shift per press in Plant 2.

• Utilize IIOT and digitization data to identify and reduce losses caused by machine breakdown, tool failures, and model changes.

2. Quality Management & System Compliance (20% of Time)

• Resolve visual defects using QC story methodologies and dimensional defects through Design of Experiments (DOE) and process capability (Cpk) improvements.

• Reduce line scrap from 2.01% to a target of 1.40%.

• Oversee and maintain international Quality Management Certifications including ISO: 9001-2015, IATF: 16949, EMS, and OSHAS procedural requirements.

3. Cost Optimization & Working Capital Management (10% of Time)

• Oversee financial targets for a sales turnover of 380 Crs, targeting an EBITDA to sales of 20.6% and PBT to Sales of 16.3%.

• Control manufacturing variable costs to strictly align with business plans:

  • OSP: < Rs 48,767/ton

  • Freight: < Rs 2,245/ton

  • Consumable stores: < Rs 12,376/ton

  • Consumable tools: < Rs 6,150/ton

  • Power: < 1,800 Units/ton

  • Packing: < Rs 3,600/ton

4. Supply Chain, Inventory & Delivery Control (20% of Time total)

• Inventory Management (10%): Tighten inventory cycles for Raw Materials (14 to 12 days), WIP (12 to 8 days), and Finished Goods (12 to 11 days) via Kanban and Vendor Managed Inventory (VMI) systems.

• Delivery Performance (10%): Raise customer On-Time In-Full (OTIF) delivery metrics from 92% to 98% while minimizing customer PPM defects.

5. Supplier & Sub-Contractor Management (10% of Time)

• Guide and support the Supplier Development and Management teams to source and monitor the existing panel of 81 suppliers.

• Establish strategic capacity augmentation and identify alternate, cost-effective vendors.

  
  

6. Safety, ESG, & Statutory Compliance (10% of Time)

• Ensure 100% compliance with statutory mandates including the Pollution Control Board, Local Municipal Authorities, and central/state legal systems.

• Advance the company's ESG score by systematically reducing power, water consumption, and hazardous/non-hazardous waste.

• Drive a "zero accident, zero pollution, zero near-miss" shop floor through Hazard Identification and Risk Assessment (HIRA).

  
  

7. Organizational Capability & Team Building (10% of Time)

• Identify skill gaps and design "build, buy, lease, or partner" capability strategies, focusing heavily on tooling skill enhancements and press maintenance.

• Foster a healthy industrial relations environment by working closely with the Trade Union and HR.

Core Competencies (Knowledge & Skills)

• Domain Knowledge: Advanced Fine Blanking processes, Heat Treatment, Double Disc/Rotary Grinding, Plasma Arc Welding, Plastic molding, TQM/TPM tools, and Cost Management techniques.

• Core Skills: Critical thinking and troubleshooting under fluctuating demands, high attention to detail, strong people development skills, innovation management, and the ability to build and nurture a thorough quality culture.