Production Manager
Erode
Production Manager
Job Description
The Senior Manager / DGM – Foundry Operations will be responsible for the overall management and performance of the foundry operations encompassing Production, Post-Production, Maintenance, Utilities, and Capital Projects. The role is accountable for achieving production targets, quality objectives, cost optimization, equipment reliability, operational excellence, safety compliance, and execution of strategic growth initiatives.
Key Responsibilities
1. Production Operations
- Lead end-to-end foundry production operations including Melting, Moulding, Core Making, Pouring, Shakeout, Fettling, Inspection, and Dispatch.
- Ensure achievement of production targets, quality standards, and customer delivery commitments.
- Optimize utilization of manpower, machinery, materials, and energy resources.
- Drive productivity improvement, process efficiency, and operational excellence initiatives.
- Coordinate with Quality, Maintenance, Supply Chain, and Commercial teams for smooth operations.
2. Operational Excellence
- Implement Lean Manufacturing, TPM, Kaizen, Six Sigma, and continuous improvement initiatives.
- Improve OEE, productivity, yield, and throughput.
- Reduce rejection, rework, scrap, and production losses.
- Drive cost optimization and process standardization across operations.
3. Quality Management
- Ensure compliance with customer quality requirements and internal quality standards.
- Reduce customer complaints, warranty issues, internal rejection, and rework.
- Lead root cause analysis and implementation of corrective and preventive actions.
- Monitor key quality performance indicators and process capability.
4. Maintenance & Utilities
- Lead preventive, predictive, and breakdown maintenance activities.
- Ensure high equipment availability and reliability across all plant operations.
- Manage maintenance of furnaces, moulding lines, sand plants, utilities, and material handling equipment.
- Improve equipment reliability, reduce downtime, and optimize maintenance costs.
- Ensure uninterrupted availability of power, compressed air, water, and other utilities.
5. Projects & Expansion
- Lead plant expansion, modernization, automation, and capacity enhancement projects.
- Manage project planning, budgeting, execution, commissioning, and stabilization.
- Drive technology upgrades, digitization, and Industry 4.0 initiatives.
- Coordinate with equipment suppliers, contractors, and consultants.
6. Safety, Health & Environment (SHE)
- Ensure compliance with all EHS policies, statutory regulations, and management systems.
- Promote a strong safety culture and zero-accident workplace.
- Conduct safety reviews, audits, risk assessments, and incident investigations.
- Ensure compliance with Factories Act, Pollution Control Board norms, ISO 14001, and ISO 45001 requirements.
7. Cost & Budget Control
- Prepare and manage annual operating and maintenance budgets.
- Monitor manufacturing costs and drive cost reduction initiatives.
- Optimize consumption of raw materials, consumables, energy, and maintenance resources.
- Ensure effective inventory management of spares and consumables.
8. Leadership & People Development
- Lead Production, Maintenance, Projects, Quality, and Support functions.
- Build a high-performance culture focused on accountability and continuous improvement.
- Develop team capability through coaching, training, and succession planning.
- Drive employee engagement, performance management, and workforce productivity.