Grade: Senior Manager

Location: Prithla, Haryana

Department: Manufacturing - Cold Forging

Reporting To: Plant Head

Role Purpose:

The Section Head - Cold Forging will be responsible for leading the complete Cold Forging operations of the assigned manufacturing section, ensuring achievement of production, quality, cost, delivery, safety, and productivity objectives. The incumbent will drive operational excellence through effective manpower management, machine utilization, process optimization, and data-driven decision-making while ensuring adherence to manufacturing standards.

Key Responsibilities:

Cold Forging Operations:

- Lead and manage end-to-end Cold Forging operations for the assigned section.

- Ensure achievement of daily, weekly, and monthly production targets while maintaining quality and delivery commitments.

- Optimize machine utilization, cycle time, productivity, and overall operational efficiency.

- Monitor production output and implement corrective actions to eliminate bottlenecks.

- Ensure smooth shift operations and effective manpower deployment.

Process Improvement:

- Drive continuous improvement initiatives to improve productivity, reduce conversion cost, and eliminate process losses.

- Lead implementation of Lean Manufacturing, TPM, Kaizen, 5S, and OEE improvement initiatives.

- Identify opportunities for process optimization and automation.

Equipment Performance:

- Coordinate closely with the Maintenance team to maximize machine uptime and equipment reliability.

- Review breakdown analysis and implement preventive actions to minimize recurring failures.

- Ensure timely preventive maintenance schedules without impacting production.

Production Planning & Execution:

- Work closely with PPC to ensure adherence to production schedules.

- Monitor production planning versus actual output and take corrective actions for deviations.

- Ensure optimum utilization of raw material, tooling, and other manufacturing resources.

Data Analysis & Performance Monitoring:

- Analyze production data, downtime, rejection, machine efficiency, and productivity trends.

- Develop action plans based on operational data to improve overall plant performance.

- Prepare and review daily, weekly, and monthly MIS reports and operational dashboards.

Quality & Process Compliance:

- Ensure manufacturing processes comply with quality standards and customer requirements.

- Work closely with Quality and Engineering teams to reduce rejection, rework, and customer complaints.

- Drive Root Cause Analysis (RCA) and implementation of corrective and preventive actions.

People Leadership:

- Lead, mentor, and develop supervisors, engineers, and shop-floor employees.

- Build a culture of accountability, discipline, teamwork, and continuous improvement.

- Identify training needs and support employee skill development.

Safety & Compliance:

- Ensure strict adherence to safety standards, statutory regulations, and company policies.

- Promote a zero-accident culture through regular safety audits and awareness initiatives.

- Ensure compliance with environmental and operational standards.

Educational Qualification:

- Full-time B.E./B.Tech in Mechanical Engineering OR Full-time Diploma in Mechanical Engineering.

Experience:

Mandatory:

- Minimum 18 years of experience in manufacturing operations.

- Hands-on experience in Cold Forging manufacturing is mandatory (Fastener industry preferred but candidates from other Cold Forging industries will also be considered).

- Experience in Production, Maintenance, or Production Planning & Control (PPC) within Cold Forging operations.

- Strong exposure to high-volume manufacturing environments.

- Experience in leading teams and managing shop-floor operations.

Desirable:

- Exposure to Heat Treatment, Plating, or other downstream processes in the fastener manufacturing value chain.

- Experience in automotive or engineering component manufacturing.

Technical Competencies:

- Strong knowledge of Cold Forging processes and equipment.

- Understanding of multi-station cold forging machines and tooling.

- Knowledge of production planning, machine utilization, and manufacturing KPIs.

- Strong analytical and data interpretation skills.

- Experience in Lean Manufacturing, TPM, OEE, Kaizen, 5S, and Continuous Improvement.

- Good understanding of manufacturing cost optimization and productivity improvement.

Key Skills:

- Cold Forging Operations Management

- Manufacturing Excellence

- Production Planning & Execution

- Data Analysis & Decision Making

- Team Leadership

- Continuous Improvement

- Problem Solving

- Cross-functional Coordination

- Cost Optimization

- Result Orientation