Head Tool Room

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Role Objective

To lead and manage the entire precision plastic components plant with full P&L responsibility, while driving end-to-end tool room operations from tool engineering, development, and manufacturing to preventive maintenance and continuous improvement. The role ensures high-quality, small precision moulds and components are delivered with world-class efficiency, reliability, and cost competitiveness. In addition to managing production, quality, supply chain, and manpower, the objective is to optimize plant profitability, enhance customer satisfaction, and support long-term business growth through operational excellence and innovation in precision moulding technologies.

Key Responsibilities

1. Tool Engineering & Design

2. Drive design and engineering of small precision moulds with high accuracy and tight tolerances.

3. Provide DFM (Design for Manufacturability) and DFA (Design for Assembly) inputs during product development.
4. Standardize tool design practices to ensure reliability and consistency.

Tool Development & Manufacturing

• Oversee complete mould development: machining, fitting, assembly, and validation.
• Manage high-precision machining processes (CNC, VMC, EDM, Wirecut, jig grinding, micro polishing).
• Validate moulds with production trials, ensuring robustness for high-volume, small-part moulding.

Tool Maintenance & Troubleshooting

• Implement preventive and predictive maintenance plans for small precision moulds.
• Lead root-cause analysis and troubleshooting of tool failures to minimize production downtime.
• Maintain complete tool history and performance records.

Quality & Process Excellence

• Ensure mould quality meets micron-level dimensional accuracy and surface finish requirements.
• Collaborate with quality team for first-off inspection, validation, and customer approvals.
• Drive continuous improvements in tool design, machining accuracy, and tool life enhancement.

Innovation & Continuous Improvement

• Introduce advanced tool-making techniques (micro EDM, high-speed machining, laser texturing).
• Optimize cycle time, tool durability, and cost competitiveness.
• Apply Lean, Six Sigma, 5S, and TPM methodologies in tool room operations.

Team & Vendor Management

• Lead and develop a skilled team of tool makers and precision machinists.
• Coordinate with external precision tool makers or suppliers for specialized jobs.
• Manage tool room budgets, resources, and cost optimization.

Education

• Diploma / B.E. / B.Tech. in Tool & Die Making, Mechanical, or Production Engineering.
• Postgraduate qualification (MBA / PGDM in Operations or General Management) will be an added advantage.

Experience

• 2025 years of experience in plastic injection moulding, with strong expertise in precision moulds and small components.
• Minimum 57 years in a senior leadership role managing tool room operations and overall plant functions.
• Proven track record of managing P&L responsibility in a manufacturing environment.

Technical Expertise

• End-to-end knowledge of tool design, tool development, manufacturing, validation, and maintenance.
• Strong exposure to precision tooling: multi-cavity moulds, hot runner systems, micro-tolerance moulds, and high-speed machining.
• Proficiency in CAD/CAM software (UG NX, CATIA, AutoCAD, MasterCAM, etc.).
• Expertise in advanced machining processes (CNC, VMC, EDM, Wirecut, Jig Grinding, Micro EDM, polishing, micro finishing).
• Hands-on understanding of injection moulding processes for high-precision, small components.
• Knowledge of automation, robotics, and lean manufacturing practices in precision moulding.

Leadership & Management Skills

• Experience in leading plant operations (production, quality, maintenance, supply chain, and manpower).
• Proven ability to manage P&L, budgeting, and cost optimization.
• Strong leadership to build, mentor, and retain high-performance teams.
• Ability to manage vendor development and external tool makers.
• Exposure to customer handling, audits, and new business requirements.

Industry Exposure

• Preferred from automotive (precision components), electrical/electronics, consumer durables, medical devices, or engineering plastics.
• Experience in Tier-1 or Tier-2 supplier environment with multinational exposure is desirable.

Behavioral Competencies

• Strong analytical and problem-solving skills.
• High energy, result-oriented mindset with focus on operational excellence.
• Ability to drive continuous improvement (Kaizen, Six Sigma, TPM, 5S).
• Excellent communication and cross-functional collaboration skills.
• Customer-oriented with the ability to deliver under demanding timelines.