Head - Manufacturing - ESR/Hot Forging Industry

Manufacturing Head will lead the entire ESR and forging operations at the Chennai facility. This position involves overseeing the end-to-end forging process, including production planning, cost estimation, and product development, while ensuring the integration of lean manufacturing principles. The individual will drive operational excellence, ensure high-quality output, and foster innovation for key forging projects, particularly for critical applications like nuclear, defense, aerospace, power and oil & gas.

Key Responsibilities:

End-to-End Operations:

- Oversee the entire forging process, from raw material handling to final product dispatch, ensuring high-quality and efficient operations.

- Manage production and process optimization for forged components, ensuring timely deliveries aligned with customer requirements.

Production Planning:

- Develop and implement production plans based on business forecasts and customer orders to meet business targets.

- Coordinate with the Production Planning and Control (PPC) team to align production schedules with customer demand and internal targets.

New Product Development:

- Drive the development and production of new forging products in collaboration with R&D and design teams, ensuring they meet customer specifications and industry standards.

- Implement continuous product improvement to enhance quality, performance, and cost effectiveness.

Cost Estimation & Market Requirements:

- Provide cost estimations for forging-related enquiries, ensuring profitability and market competitiveness.

- Evaluate market requirements and adjust production processes to meet emerging trends and customer demands.

Lean Manufacturing Implementation:

- Implement lean manufacturing techniques to enhance operational efficiency, reduce waste, and improve product quality.

- Lead continuous improvement initiatives across the forge shop.

Responsible for PPC, Marketing & Quality:

- Collaborate with the PPC team to ensure seamless production flow and to meet customer deadlines.

- Work closely with the teams to understand market demands and customer expectations.

- Ensure that all products meet stringent quality standards in coordination with the Quality Control department.

Troubleshooting & Maintenance:

- Lead troubleshooting and problem-solving efforts for any operational or quality issues in the ESR/forge shop.

- Oversee regular maintenance schedules to ensure the smooth functioning of forging equipment and machinery.

Management Information Systems (MIS):

- Develop and maintain MIS for the ESR/forge shop to track production, inventory, and performance metrics.

- Prepare and present regular reports on key operational parameters to senior management.

Key Qualifications and Skills:

Educational Qualification:

- Bachelor's degree in Mechanical Engineering or Metallurgical Engineering. A Master's degree is a plus.

Experience:

- Minimum 10 years of experience in the ESR / forging industry, specifically with specialty steels, stainless steel, and superalloys.

- Proven experience in handling major forgings for critical applications such as nuclear, defense, oil & gas, and other high-stakes industries.

- Expertise in forging project management, including commissioning, operations, and maintenance.

Technical Expertise:

- Deep knowledge of Electro-slag Remelting (ESR) and forging technologies.

- Expertise in forging process design, cost estimation, and material selection for high performance alloys.

- Strong understanding of forging tools, dies, and equipment maintenance.

Leadership & Management Skills:

- Strong leadership skills with a track record of managing large teams in a high-production environment.

- Experience in production planning, budget management, and resource allocation.

- Ability to work cross-functionally with PPC, Marketing, R&D, and Quality Control teams to ensure efficient operations.

Problem-Solving & Decision Making:

- Exceptional troubleshooting skills for forging-related issues, ensuring minimal downtime and optimal productivity.

- Experience in root cause analysis and implementing corrective actions for process optimization.

Soft Skills:

- Strong communication and interpersonal skills.

- Ability to work under pressure and meet demanding production deadlines.

- Proactive, solution-oriented approach with a focus on continuous improvement.

Additional Requirements:

- Experience in Forging for Critical Applications such as nuclear, defence, aerospace, power and oil & gas sectors.

- Expertise in Forging Project Commissioning: Managing and overseeing large-scale forging projects from design to commissioning and operationalization.