Operation Head

Job Description

Job Title: Operations Head

Department: Operations

Location: Pune, Chakan

Experience:15-20 Yrs.

Qualification:B.E. (Mechanical /Industrial /Production) and MBA.

Certified Welding Engineer (CWE) / IWE is added advantage

Critical Skills & Personal Attributes

The Candidate must be a seasoned professional with proven success in Heavy Fabrication, Pressure Vessels, Process Equipment, Heavy Engineering, etc any of the sector.

The role carries end-to-end accountability for both Top Line (Order Execution, Customer Satisfaction) and Bottom Line (EBITDA, Cost Control, Productivity) performance.

He must have experience Manufacturing Operations and Engineering, Various Welding Process, Cost Control, Welding Methodology (SMAW, GTAW, GMAW, SAW, Etc.), NDT and Quality Assurance, Material Management, Heavy Fabrication, People Management and Shop Floor Management, CFT & interplant coordination in heavy fabrication industry.

He should have hands on experience in Lean Manufacturing and Lean Tools / methodologies.

Proficient in monitoring manufacturing operations as per ASME, ASTM, EN codes with key focus on top line & bottom-line profitability by implementing profitability improvement initiatives, achieving plant KPIs, monitoring OEE and rejection rework control.

Able to understand manufacturing cost structures, estimation, variances analysis and financial metrics. Also have knowledge heavy plate bending, plasma / laser cutting, fit up sequences, distortion control and post weld heat treatment (PWHT). Has exposure to modern fabrication technologies, robotic welding systems, SAP, PPC software, etc.

Hands-on experience in appraising the prevalent production systems / processes, to reduce COPQ by identifying training areas of welders and fitters, result-oriented measures for improving team skills and performance.

Main responsibility

1. Plant Accountability:

• Own and drive the business unit's revenue and profitability targets, deliver annual operating plans, budgets, and strategic growth initiatives and review time to time.
• Ensure achievement of Top Line targets through on-time execution of customer orders.
• Focus on productivity enhancement, waste reduction, manpower cost control and reduction, cost optimization, and operational efficiency, working capital optimization, throughput time reduction and inventory control.

2. Operations Management:

• Lead complete fabrication operations from raw material receipt to final dispatch.
• Ensure achievement of production targets with optimum utilization of manpower, machinery, and resources.
• Establish robust manufacturing systems and operational controls.
• Improve throughput, productivity, OEE, cycle times, and capacity utilization.
• Drive operational excellence initiatives using Lean Manufacturing, Six Sigma, TPM, Kaizen, and Value Engineering.
• Ensure adherence to production schedules and customer commitments.

3. Welding & Fabrication Excellence: Must Possess Strong awareness in:

• Welding Engineering and Welding Technology (SMAW, GTAW, GMAW, SAW, Etc.),
• Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR).
• Welder Qualification Records (WQR), Welding Process Selection and Optimization.
• Distortion Control Techniques, Heat Treatment Processes (PWHT).
• Fabrication Methodologies for heavy structures and equipment.
• Welding Productivity Improvement Techniques.

4. Knowledge of materials like Carbon Steel, High Strength Low Alloy Steel, Stainless Steel, Chrome, Nickel Alloys, Etc.

5. Expert working knowledge of various standards like ASME, AWS Codes, API, ISO, EN, NACE requirements and Customer Specific Fabrication Standards.

6. Quality Management:

Ensure high standards of quality and compliance with Quality Control Drive zero-defect manufacturing culture.

Ensure successful customer inspections and third-party audits. Monitor and improve first-pass yield and rejection rates. Lead root cause analysis and corrective action programs.

Have Knowledge of Inspection and NDT like RT, UT, PT, MPT,

7. Production planning and management through coordinating with cross functional teams, interplants, customers, resolve bottlenecks impacting the OTIF through effective resource planning and load balancing.

8. Establish and maintain safety, health & environment best practices through compliance with statutory and regulatory requirements, by driving zero harm / accident across the plant through safety reviews and risk assessments. Promote safe welding and fabrication practices in plants.

9. Leadership and People Development:

Lead multi-functional teams including Production, Welding, Planning, Quality, Maintenance, stores etc. Develop second-line leadership and succession plans. Drive employee engagement and performance culture. Build accountability and ownership across all levels.

10. Ensure Continuous improvement through various techniques like Lean Mfg., Kaizen, automation initiatives, benchmarking best practices, performance dashboards & KPI Reviews.

Work Styles

1. Integrity Job requires being honest and ethical.

2. Dependability Job requires being reliable, responsible, and dependable, and fulfilling obligations.

3. Analytical Thinking Job requires analyzing information and using logic to address work-related issues and problems.

4. Advanced troubleshooting and multi-tasking skills Job requires a high level of problem-solving skills and ability to do multi-tasking

5. Collaboration Work effectively across departments, fostering teamwork and open communication.