Manager - Production (TCD)

Roles & Responsibilities:

A. Production Strategy, Planning & Execution

• Own end-to-end production performance for tower crane fabrication, welding, machining coordination, blasting, painting, sub-assembly and final assembly.
• Translate monthly/weekly production requirements into process-wise capacity, manpower, machine and shift plans in coordination with PPC/IE.
• Ensure production execution as per approved BOM, drawings, routing, process flow, standard times and production orders.
• Establish and monitor daily/weekly/monthly production targets and recovery plans for deviations.
• Identify and eliminate bottlenecks related to material, manpower, machine, method, tooling and capacity.
• Ensure controlled WIP flow between fabrication, surface treatment and assembly processes.
• Ensure manufacturing readiness before production release, including material, drawings, tooling, fixtures, equipment, manpower and inspection readiness.

B. Fabrication & Welding Process Management

• Lead manufacturing of tower sections, jib sections, counter-jib, slewing platforms, machinery frames, outriggers, brackets and other structural assemblies.
• Ensure compliance with approved WPS/PQR, welding parameters, qualified welder requirements and applicable welding standards.
• Control critical welding parameters including preheat, interpass temperature, current, voltage, travel speed, heat input and welding sequence.
• Ensure control of fit-up, root gap, alignment, weld size, distortion and dimensional stability.
• Ensure welding consumable identification, storage, baking, issue and traceability.
• Monitor weld repair/NDT rejection and drive systematic reduction of welding defects.
• Establish effective distortion-control, fixture-control and first-off approval practices.

C. Dimensional & Process Control

• Ensure manufacturing compliance with drawing requirements, GD&T, tolerances and defined CTQs.
• Establish controls for straightness, flatness, squareness, parallelism, hole diameter, hole pitch, positional accuracy and structural alignment.
• Ensure first-off, in-process and final dimensional verification.
• Ensure availability, capability and periodic verification of gauges, fixtures, templates and measuring equipment.
• Drive Poka-Yoke and error-proofing for critical/repetitive manufacturing operations.

D. Blasting & Painting Process

• Own production performance for surface preparation, shot blasting, primer, intermediate coat, top coat and curing.
• Ensure compliance with approved coating systems and process specifications.
• Control blasting parameters, surface preparation, surface profile and environmental conditions.
• Ensure control of paint mixing ratio, pot life, application parameters, DFT, inter-coat interval and curing.
• Drive improvement in paint consumption, booth utilization, throughput, rejection and rework.

E. Assembly Process Management

• Ensure assembly is executed according to approved BOM, drawings, routing and Work Instructions.
• Control critical assembly parameters including fitment, alignment, clearances, bolt torque, lubrication, pin/bushing fit and functional condition.
• Ensure operator self-inspection and Quality verification for identified critical characteristics.
• Ensure proper handling and protection of components throughout assembly.

F. Quality & Process Governance

• Own production-related quality performance while maintaining independent Quality verification/release.
• Ensure adherence to Process Flow, PFMEA, Control Plan, Work Instructions, Inspection Plans and Quality Gates.
• Monitor and improve FPY, internal PPM, rework, scrap, welding defects, dimensional rejection and assembly defects.
• Lead structured RCA using 8D, 5-Why, Fishbone, Pareto and other problem-solving methodologies.
• Ensure effective corrective/preventive action and standardization of improvements.
• Prevent unauthorized process deviations, rework or component modifications.

G. Quality Gate, NCR & Rework Management

• Ensure compliance with defined manufacturing Quality Gates from material release through final product release.
• Ensure NOK material is identified, segregated and controlled.
• Ensure rework/repair is performed only against approved instructions and authorized disposition.
• Ensure reworked components undergo defined reinspection and release.
• Ensure NCR, deviation, concession and rework records are linked to relevant production orders/serial numbers.

H. Capacity, Productivity & Cost Management

• Establish process capacity based on cycle time, available hours, efficiency, manpower and equipment capability.
• Monitor OEE, cycle time, output/man-hour, machine utilization and bottleneck capacity.
• Drive line balancing, layout optimization, material-flow improvement and manpower optimization.
• Reduce manufacturing losses related to waiting, movement, setup, downtime, rework, scrap and excess consumption.
• Own production cost performance including labour, welding consumables, paint, gas, energy, overtime and rework.
• Identify and justify CAPEX requirements for capacity, quality and productivity improvement.

I. Manpower & Competency Development

• Define manpower requirements based on production volume, process loading and shift pattern.
• Maintain and improve production skill matrix.
• Ensure qualified personnel for welding, fabrication, painting, assembly and other critical operations.
• Develop multi-skilled workforce and succession capability.
• Identify skill gaps and establish technical training/qualification plans.
• Optimize permanent and contractual manpower deployment.

J. Equipment, Tooling & Maintenance

• Ensure availability and capability of production-critical equipment, cranes, welding machines, fixtures, blasting and painting systems.
• Coordinate with Maintenance for preventive maintenance and equipment reliability.
• Monitor breakdown, MTBF, MTTR and equipment availability.
• Participate in URS, technical evaluation, FAT/SAT, commissioning and process validation for new equipment.
• Ensure production tooling and fixtures remain capable and fit for use.

K. New Product / Process Industrialization

• Support NPD and product transfer activities through DFM/DFA, process feasibility, capacity assessment and manufacturing risk evaluation.
• Lead preparation/review of:
  • Process Flow
  • PFMEA
  • Control Plan
  • Work Instructions
  • Inspection Plans
  • Quality Gates.
• Coordinate pilot production, first-off approval, process validation and series-production release.
• Ensure lessons learned from existing products are incorporated into new processes.

L. Supplier & Cross-Functional Coordination

• Coordinate with PPC, Quality, IE, SQM, Purchase, Engineering, Maintenance, Logistics, Customer Quality and Finance.
• Support supplier development for production-critical components/processes.
• Escalate material, supplier, quality and capacity risks affecting production delivery.
• Drive cross-functional closure of chronic manufacturing issues.

M. Safety & Compliance

• Own production safety performance and ensure compliance with applicable EHS requirements.
• Ensure safe practices for heavy lifting, welding, gas cutting, grinding, blasting, painting, crane operation and material handling.
• Ensure PPE, LOTO, fire protection, chemical handling and safe lifting requirements are implemented.
• Drive near-miss identification, risk reduction and corrective actions.

N. Continuous Improvement & Digitalization

• Lead Lean Manufacturing, VSM, Kaizen, 5S, Poka-Yoke and standard-work initiatives.
• Drive reduction of manufacturing waste and process variability.
• Promote ERP/MES-based production reporting and traceability.
• Establish data-driven production dashboards and loss analysis.
• Standardize successful improvements across relevant production processes.

Qualification and Education Requirements:

Essential

• Bachelor's Degree in Mechanical Engineering / Production Engineering / Manufacturing Engineering / Industrial Engineering.
• Strong technical understanding of heavy fabrication, welding and mechanical assembly.

Preferred

• Master's / PG qualification in Manufacturing / Operations / Industrial Engineering.
• IWE / IWT / Welding Technology qualification – highly desirable.
• Lean Six Sigma certification.
• Formal training in:
  • PFMEA
  • Control Plan
  • SPC
  • MSA
  • 8D / RCA
  • Manufacturing process improvement.
• Knowledge of ISO 9001, ISO 3834 and DIN EN 1090.

Experience:

• 10–15+ years of relevant manufacturing experience, preferably in heavy engineering/heavy fabrication.
• Minimum 5 years in Production/Manufacturing Managerial responsibility.
• Strong hands-on experience in:
  • Structural fabrication
  • Welding
  • Dimensional control
  • Machining interface
  • Blasting & painting
  • Mechanical assembly.
• Experience managing multi-shift production operations.
• Proven experience in capacity planning, manpower planning, production scheduling and productivity improvement.
• Demonstrated track record of improving SQDCP performance.
• Experience with production KPIs, OEE, cycle-time improvement and cost reduction.
• Experience in new product/process industrialization is preferred.

Experience in tower cranes, construction equipment, heavy machinery, material handling, wind-energy equipment or similar heavy-engineering products is highly preferred

Have we awoken your interest? Then we look forward to receiving your online application. If you have any questions, please contact Saurabh Padmakar Kulkarni.

One Passion. Many Opportunities.