Senior Manager

Senior Manager AGM - Plant Operations Department Manufacturing Operations Quality Employment Type Full Time Location India Reporting To Anoop Agarwal Description 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 Key Responsibilities 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 Skills Knowledge and Expertise Technical Engineering Skills Degree in Mechanical Electrical Industrial Engineering or equivalent plus strong hands-on experience in motor manufacturing or heavy electromechanical equipment Experience with advanced reverse engineering reading preparing verifying technical drawings 3D modelling CAD measurement tools design for manufacturability DFM Knowledge of materials used metals insulation materials sealing materials oil types etc Understanding of processes specific to oil-filled submersible motors stator rotor winding impregnation oil filling sealing balancing testing under submerged or sealed conditions Process Manufacturing Skills Process engineering process flow mapping bottleneck analysis plant layout design Value engineering cost-reduction mindset In-process quality control SPC test measurement reliability engineering Maintenance engineering preventive predictive maintenance equipment reliability Management Leadership Proficiency in setting up a facility operations staffing process documentation SOPs Strong planning organizational skills Leadership and people management coaching mentoring performance management Cross-functional collaboration with design R D procurement quality logistics Communication Delivers accurate clear and concise messages orally and or in writing Problem Solving Uses a logical systematic search for the source of a problem determining the most likely cause by eliminating potential causes of a problem Decision Making Identifies and understands issues problems and opportunities compares alternatives and makes timely decisions Project Management Develops project plans schedules and budgets and keeps project team on task Manages risks and issues Prepares and delivers project status reports Education and Experience Bachelor s degree in mechanical electrical industrial engineering A master s or specialized qualification is a plus Experience of 13 - 17 years in manufacturing operations preferably in motor electrical machinery or comparable heavy equipment For a new facility setup prior experience in commissioning greenfield projects is highly preferred Demonstrated experience in reverse engineering value engineering plant layout process quality setting up production lines leading from design to full production Familiarity with continuous improvement methodologies Lean Six Sigma etc Work Location Vadodara Ahmedabad The selected candidate will initially be based at Vadodara Gujarat After successfully transitioning into the role they will be required to move to Ahmedabad Gujarat to oversee the greenfield project for establishing a new manufacturing facility