Assistant Production Manager

Company/Industry: Glass Processing / Automotive Manufacturing
Position: Assistant Manager Encapsulation Production
Role Description: Lead Encapsulation Production
Experience: 4–8 years
Qualification: B.E./B.Tech
Preferred Knowledge: CIPET

Role Purpose

To ensure smooth process operations and achieve production results.

Key Responsibilities

1. Safety

• Ensure safe operating practices and maintain an accident-free workplace.
• Complete safety countermeasures on time.
• Identify and eliminate machine-related hazards through danger prediction and KY activities.
• Create safety awareness among shop-floor employees.
• Monitor reportable/recordable injuries, near-miss reporting, safety audits, Kaizens, TPM Fuguai identification and rectification, and machine risk assessments.

2. Quality

• Proactively reduce defect generation and defect flow to the next process.
• Ensure adherence to customer quality requirements and standards.
• Train operators in systematic problem-solving approaches.
• Ensure adherence to TQM systems and reduce PPM.
• Monitor process yield, next-process claims, QACRs, quality circles, TQM documentation, and product audit scores.

3. Productivity

• Operate machines at defined cycle times.
• Improve machine availability and eliminate rework.
• Perform troubleshooting and failure analysis using systematic and analytical tools.
• Monitor average production per shift, available-time utilization, rework percentage, and PDCA improvement examples.

4. Manpower Development

• Train operators on machines, systems, TPM, Kaizen, 5S, and safety.
• Provide on-the-job training related to machine operations.
• Encourage 100% employee participation in quality circles.
• Maintain skill matrices, operator observance audit sheets, suggestions, and quality-circle activities.

5. Systems Audit

• Develop innovative process-improvement ideas.
• Ensure process parameters remain within standard limits.
• Update control charts daily.
• Certify operators and inspectors.
• Maintain shop-floor 5S standards and TPM activities.
• Monitor process precision studies, machine process audits as per PQCT, control-chart display boards, operator/inspector certification lists, 5S and safety audits, Office TPM activity boards, Initial Control Pillar, and Quality Maintenance.

6. Shop-Floor Control

• Ensure operational records are maintained according to systems and job standards.
• Communicate daily shop-floor issues to operators.
• Coordinate with Maintenance and Quality teams to resolve daily plan-versus-actual gaps.
• Conduct rejection analysis and execute monthly improvement plans.
• Improve shop-floor 5S levels.
• Monitor non-conformity reports, daily toolbox meetings, daily CFT meetings, red-bin analysis, monthly improvement-plan meetings, and 5S audit scores.

Required Knowledge and Skills

• Good technical knowledge of machines and glass-processing operations.
• Knowledge of injection moulding (encapsulation) processes.
• Knowledge of quality standards, systems, and procedures, including TQM, TPM, TS 16949, and ISO 14001.
• Technical skills related to production and process operations.

Qualification and Experience

• Education: B.E./B.Tech
• Experience: 4–8 years
• Additional requirement mentioned: CIPET

Key Internal and External Interactions

• Internal: Production Planning, Mechanical and Electrical Maintenance, Quality, New Model Development, Projects, R&D, HR and Administration.
• Customers/Next Process: Next-process teams.
• External: All process owners and relevant external stakeholders/vendors, as applicable.