Production Head
3 hours ago
Head of Production Foundry (Automotive Castings)
Role Summary
The Head of Production is responsible for the entire production operations of the foundry, ensuring efficient, safe, and cost-effective manufacture of iron castings that comply with automotive industry standards (ISO/TS 16949, IATF This role leads production, maintenance, and process teams to achieve excellence in Quality, Cost, Delivery, Safety, and Morale (QCDSM).
Key Responsibilities
1. Production Planning & Control
- Prepare and execute daily, weekly, and monthly production plans aligned with customer schedules.
- Coordinate with Sales, Planning, and Supply Chain for raw material and dispatch alignment.
- Monitor melting, molding, core making, fettling, and machining processes to ensure balanced flow and minimal bottlenecks.
- Track OEE (Overall Equipment Effectiveness) and productivity metrics.
2. Process Optimization & Efficiency
- Drive Lean Manufacturing, Kaizen, TPM, and 5S initiatives.
- Identify and eliminate process wastes (scrap, rework, downtime, excessive energy consumption).
- Ensure optimal utilization of manpower, machines, and materials.
- Implement automation and digitalization projects (Industry 4.0) for process improvement.
3. Quality Assurance
- Collaborate with the Quality Head to ensure defect-free castings.
- Maintain process capability (Cp, Cpk) and adherence to control plans and work instructions.
- Lead cause analysis (8D, Fishbone, Pareto) for internal and customer complaints.
- Ensure metallurgical quality: composition, microstructure, and mechanical properties.
4. Maintenance & Equipment Reliability
- Coordinate with Maintenance to maximize equipment uptime.
- Approve and review preventive and predictive maintenance schedules.
- Ensure quick resolution of breakdowns and furnace-related issues.
5. Safety, Health & Environment (SHE)
- Enforce foundry safety protocols, PPE usage, and safe handling of molten metal.
- Conduct safety audits, risk assessments, and accident investigations.
- Ensure environmental compliance (emissions, sand reclamation, waste disposal).
6. Manpower Management
- Supervise and mentor production engineers, shift in-charges, and operators.
- Define KPIs and conduct performance reviews for production staff.
- Drive training and skill development in foundry practices, equipment operation, and safety.
- Manage manpower deployment, shift planning, and overtime control.
7. Cost Control
- Monitor production costs per ton/casting, yield losses, and energy utilization.
- Initiate cost reduction projects through process improvements or sourcing changes.
- Prepare and control departmental budgets for consumables, maintenance, and utilities.
8. Customer & Cross-functional Coordination
- Collaborate with Quality, R&D, and Customer Service for new part developments and audits.
- Support PPAP, trial castings, and product validation for new models.
- Participate in customer audits and technical reviews.
9. Compliance & Documentation
- Ensure compliance with IATF 16949, ISO 14001, ISO 45001 and other standards.
- Maintain production records, process logs, and performance dashboards.
- Lead internal and external audits related to production systems.
Authority
The Head of Production has the authority to:
- Approve production schedules and manpower deployment.
- Authorize machine shutdowns/startups in coordination with Maintenance.
- Approve consumption of materials, energy, and tools within budget.
- Sanction overtime and shift adjustments.
- Recommend hiring, promotion, or disciplinary actions for production personnel.
- Approve capital expenditures related to production equipment (within delegated limits).
- Stop production if safety or quality is compromised.
Reporting Structure
- Reports to: Plant Head / General Manager – Operations / Managing Director
Direct Reports:
Production Managers / Shift Engineers
- Process Engineers
Supervisors / Operators
Interfaces with: Quality, Maintenance, SCM, HR, Safety, R&D, and Finance departments
Key Performance Indicators (KPIs)
Category
KPI Metrics
Productivity
Tons per man-hour, OEE, yield (%)
Quality
Rejection %, customer complaints, Cp/Cpk
Cost
Cost per ton, energy per ton, consumables usage
Qualifications
- Education: Diploma or Bachelor's in Mechanical/Electrical Engineering.
- Experience: 20+ years in foundry or heavy engineering industries.
Application Details
Interested candidates are requested to email their updated resumes to:
, ,
Note: Only shortlisted candidates will be interviewed further.
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