Plant Manager ( Must have experience in atmospheric heat treatment)

Jobinhalt

(Must have) Candidate Profile

• Should be a metallurgical engineer
• Extensive experience in atmospheric heat treatment processes like carburizing, carbonitriding, gas nitriding, hardening and tempering. A minimum of 10-12 years of relevant experience is required.

Roles and Responsibilities

1. Operational deliverables -

Key responsibilities include handling of entire operations i.e. production, quality, maintenance, purchase and supply chain. The details are as follows;

2. Safety

• Initiate / conduct regular monthly safety reviews and audits (internal & external)/ Ensure compliance for the same.
• Implement well defined steps to improve the overall safety in the plant.
• Support imparting of requisite training to concerned operatives, supervisors, managers and maintenance staff.

Productivity

• Maintain Plant OEE @ 90% - Capture, analyze and address idle hours for improvement through structured action plan methodology.

Quality Management

• IATF:16949 certification and maintenance in the plant
• Maintain CQI-9 certification (self-assessment) for the plant at all times.
• Draft & implement quality plan for raw material / fixtures/ consumables, incoming customer material, in-process control, secondary processes (viz. shot blasting, cleaning), out-going customer material / dock audit & packaging.
• Initiate quarterly internal process and system audits
• Quality data capturing & tracking of FTR & NC, analyze, demonstrate detailed usage of standard quality tools for root cause analysis.
• Cost of poor quality viz. internal rework, rejections / technical debit notes costs should be within 1 % of sales.
• Quarterly updates to top 10 customers on performance metrics viz. cost, quality & delivery.

Fixture Management

• Responsible for supplier development, supplier rating, life cycle analysis, maintain optimum inventory (WIP + stock), usage within budget.
• Idle hours due to fixtures to be tracked and minimized.

Cost Performance

• Maintain budgeted operating costs (VC + other factory costs).
• Review daily consumption, idle hours, fixture availability, contract labor and consumable stocks.
• Yield improvement - improve low yield products from red to yellow to green.
• Develop and implement specific cost reduction project to reduce VC / operating costs.

Maintenance Management

• Zero equipment downtime through proper / religious implementation of PM on monthly / quarterly / half yearly / annual basis.
• MTTF, MTBF, equipment health checks, furnace calibration - TUS, SAT, process equipment calibration, SCADA.
• Maintain critical spares at all times. Cost efficient spares management - optimum inventory and critical spares management.

People Development

• Work for people development through mentoring, guidance, and training and up gradation of skills.
• Administer their yearly through performance appraisal (PMS).
• Foster & ensure CFT & team work across all departments.
• Driving accountability across all levels (operators, supervisors, managers production, quality, maintenance & supply chain).
• Maintain culture /moral & discipline of the plant
• Identify training needs & ensuring adequate training is given to all key personnel for skill development & productivity.

System Implementation

• Implement & maintain plant systems as per IATF 16949, ERP, Safety, Kaizen, Suggestion scheme, 5S, TPM, best practices (learning from other plants) , displays, upkeep / house-keeping, monthly MIS, DPR & meetings, smooth coordination between various CFT, healthy & safe working conditions, plant certifications at all times. B
• Ensure compliance and plant readiness as per customer specific requirements and 2nd & 3rd party audit requirements at all times.
• 100% Implementation of core business development tools like APQP, PPAP, FMEA & use of quality defect analysis & implementation tools in all existing and new development programs.

Sales Support and New Business Development

• Ensure good & effective customer communication.
• Support with regular customer visits to existing and new customers for technical discussions, support and relationship building.
• Responsible for and oversee the entire business development activity for the plant.
• Work with the Business Development team to identify and develop new business opportunities for CHT, Carbo-nitriding, Hardening & Tempering & Gas Nitriding.
• Support with technical feasibility for all critical RFQs and support for commercial offers and finalization of the business.
• Support end to end development of the process/s for the new parts/ business and formal approval from the customer.
• Streamline business development activities - quick turnaround, first time right, maintain development dash board.

Customer support

• Drive customer satisfaction through OTD & quality performance (PPM).
• Improve customer response on quality issues (through visits, 8D, submission of quality records).
• Cost reduction through VA-VE projects (share with customers) & technical support for ongoing issues and new development.