Head Forging

Role & responsibilities

Job Description: Head Forging

Position: Head Forging
Industry: Manufacturing Steel Division
Location: Hyderabad, Telangana
Experience: 15+ Years
Function: Manufacturing / Production / Forging Operations
Reporting To: Plant Head / Business Head

Job Summary

We are looking for an experienced and dynamic Head Forging to lead and manage forging operations within our Steel Division at Hyderabad. The ideal candidate will have extensive experience in forging operations, production planning, process optimization, quality management, and team leadership within a steel or heavy manufacturing environment.

The incumbent will be responsible for overseeing end-to-end forging operations, ensuring production efficiency, product quality, workplace safety, cost optimization, and on-time delivery while driving continuous improvement initiatives.

Key Responsibilities

1. Forging Operations & Production Management

• Lead and manage end-to-end forging operations, ensuring efficient utilization of manpower, machinery, and resources.
• Develop and execute production plans to meet business targets, quality standards, and delivery schedules.
• Oversee forging processes, including heating, billet preparation, hot forging, trimming, heat treatment coordination, and associated operations, as applicable.
• Monitor production output, cycle time, rejection rates, and overall equipment effectiveness (OEE).
• Ensure optimum utilization of forging presses, hammers, furnaces, and related equipment.

2. Process Optimization & Operational Excellence

• Drive continuous improvement initiatives to improve productivity, reduce cycle time, and minimize material wastage.
• Identify opportunities for process improvement, energy conservation, and cost reduction.
• Implement Lean Manufacturing, 5S, Kaizen, TPM, and other operational excellence practices.
• Establish and monitor key performance indicators (KPIs) for forging operations.

3. Quality Management

• Ensure compliance with established quality standards, customer specifications, and applicable industry requirements.
• Reduce rejection, rework, and scrap through root cause analysis and corrective and preventive actions.
• Work closely with Quality and Engineering teams to resolve process-related quality issues.
• Ensure proper process control, traceability, and documentation throughout production.

4. Maintenance & Equipment Management

• Coordinate with the Maintenance team to ensure equipment reliability and minimum downtime.
• Drive preventive and predictive maintenance practices for forging equipment and furnaces.
• Support equipment upgrades, capacity expansion, tooling improvements, and new process implementation.

5. Safety & Compliance

• Ensure strict adherence to industrial safety standards, particularly for hot forging, furnace operations, material handling, and heavy equipment.
• Promote a strong safety culture and ensure compliance with applicable statutory and environmental requirements.
• Conduct regular safety reviews, risk assessments, and corrective action follow-ups.

6. Team Leadership & Development

• Lead, mentor, and develop production managers, engineers, supervisors, and shop-floor teams.
• Establish clear performance objectives and accountability across the department.
• Identify training needs and improve technical competencies and workforce productivity.
• Foster collaboration across Production, Quality, Maintenance, Planning, and Supply Chain functions.

7. Cost Control & Business Performance

• Prepare and monitor departmental budgets, production costs, and resource utilization.
• Drive initiatives to reduce conversion costs, consumable costs, energy consumption, and manufacturing losses.
• Review daily, weekly, and monthly production performance and present operational reports to senior management.

Educational Qualifications

• B.E./B.Tech in Mechanical Engineering, Metallurgical Engineering, Production Engineering, or a related discipline.
• A postgraduate qualification in Operations or Manufacturing Management would be an added advantage.

Required Experience & Skills

• Minimum 15+ years of experience in manufacturing, preferably in the steel, forging, automotive components, heavy engineering, or allied industries.
• Significant hands-on experience in forging operations and production management, preferably in a steel manufacturing environment.
• Proven experience in managing large-scale manufacturing operations, production teams, and shop-floor activities.
• Strong understanding of forging processes, tooling, metallurgy, heat treatment, quality systems, and manufacturing technologies, as applicable.
• Experience in production planning, capacity utilization, cost control, process improvement, and productivity enhancement.
• Knowledge of Lean Manufacturing, TPM, 5S, Kaizen, and root cause analysis methodologies.
• Strong leadership, problem-solving, analytical, and decision-making capabilities.
• Ability to work effectively with cross-functional teams and deliver operational targets.

Key Performance Indicators (KPIs)

• Production output and achievement of production targets.
• Overall Equipment Effectiveness (OEE) and machine utilization.
• Rejection, rework, and scrap reduction.
• Manufacturing cost and energy consumption per unit.
• On-time delivery and adherence to production schedules.
• Workplace safety performance and compliance.
• Implementation of productivity and continuous improvement initiatives.

Preferred candidate profile

Preferred Candidate Profile

The ideal candidate will be a technically strong and results-oriented manufacturing professional with proven leadership experience in forging operations, preferably within a steel or heavy engineering manufacturing setup. The candidate should be capable of managing complex production operations, leading large teams, improving manufacturing efficiency, and delivering quality and cost targets.

Work Location: Hyderabad, Telangana.

Interested candidates can share across your updated profile to my email id (ie) [email removed] / [phone removed]