Lead Coater

ACG World; Satara; On-site; INR 1,400,000 - 2,200,000; Full time

Job summary

ACG World in Satara, Maharashtra, India, seeks a Senior Production/Operations Leader to drive safety, quality, and on-time delivery. You will lead engineers and contract workforce, plan capacity, and implement Lean initiatives to improve productivity and reduce costs.

You will collaborate with Design, PPC, Quality, and Sales to ensure smooth end-to-end production, and will be responsible for achieving annual targets and sustaining a zero-accident culture.

Qualifications

• BE and MBA are required.
• 12–15 years of experience in production/operations.
• Experience in Lean manufacturing and continuous improvement.
• Strong cross-functional coordination and project management skills.

Responsibilities

• Drive and ensure overall shop floor safety and Zero Accident culture.
• Lead and manage a team of Engineers, Plant Associates, and Contract Workforce to meet targets.
• Plan and coordinate daily operations with production teams for timely execution.
• Coordinate cross-functional with Design, Purchase, PPC, Projects, Stores, Logistics, and Sales.
• Prepare and execute monthly production capacity planning.

Skills

Production Planning

Capacity Planning

Lean Manufacturing

5-Why / CAPA

Kaizen

Cross-functional Leadership

Education

BE

MBA

Tools

ERP / SAP

Job description

Job Objective

To lead and manage Production operations with a strong focus on safety, quality, delivery, cost, and people development, by driving a zero-accident culture, ensuring on-time and right-first-time execution of production plans, optimizing resources and capacity utilization, strengthening cross-functional coordination, and embedding a culture of continuous improvement and Lean manufacturing to enhance customer satisfaction, operational excellence, and business performance.

Primary Responsibilities

• Drive and ensure overall shop floor safety by promoting a “Zero Accident Culture” and motivating teams to identify and report Near Misses, Unsafe Acts, and Unsafe Conditions.
• Lead and manage a team of Engineers, Plant Associates, and Contract Workforce to achieve annual business and production targets through optimal utilization of manpower, materials, and machines.
• Plan and coordinate daily operations through Gemba meetings with production teams to review weekly and monthly production plans, ensuring timely execution across fabrication, assembly, IO, ITR testing, trials, FAT, and final machine dispatch.
• Coordinate cross-functionally with Design, Purchase, PPC, Projects, Stores, Logistics, and Sales for end-to-end order execution.
• Prepare and execute monthly production capacity planning to manage workload fluctuations and optimize manpower deployment.
• Ensure stage-wise assembly inspections and final inspections as per QAP to maintain and improve product quality and market competitiveness.
• Review and publish weekly inventory reports for execution centres and conduct cross-functional reviews with Stores, Purchase, and Engineering teams to control inventory levels and drive consumption of non-moving and slow-moving inventory.
• Lead the Continuous Improvement and Lean Manufacturing initiatives in production such as 6S, Work Standardization, and Lean Material Flow; identify wastes (Muda), its elimination and Kaizen improvements.
• Collaborate with Quality and service teams to resolve critical customer complaints and ensure root cause analysis and CAPA implementation.

Key Result Areas

• Drive Zero Accident culture and improve safety compliance on shop floor
• Achieve annual production and business targets
• Improve OTD (On-Time Delivery) for machines and assemblies
• Optimize manpower, machine, and material utilization
• Improve capacity utilization and production flexibility
• Improve First Time Right (FTR / FPY) and reduce rework and rejection
• Improve inventory turnover and working capital efficiency
• Drive Lean, 6S, and Kaizen culture across production
• Deliver measurable productivity, quality, and cost improvements
• Ensure timely closure of customer complaints with effective CAPA
• Improve team skill levels, engagement, and ownership

Key Interfaces

Internal Interfaces

External Interfaces

• Design / Engineering
• Production (Fabrication, Assembly, Testing)
• Quality
• PPC (Production Planning & Control)
• Purchase / SCM
• Stores & Logistics
• Projects / Program Management
• Sales & CRM
• NPD / R&D
• HR
• Finance
• EHS / Safety
• Customers
• Subcontractors / Job Workers
• Auditors (Customer, ISO, Safety, and statutory audits)
• Consultants

Technical Competency

• Production Planning & Capacity Planning
• Inventory control, Material flow management
• Manufacturing operations (Fabrication, Assembly, Testing, FAT)
• Customer FAT, trials & compliance management
• Lean Manufacturing, 6S & Kaizen implementation
• Process improvement & productivity enhancement
• Quality systems, QAP
• ERP / SAP usage for production & inventory
• Root Cause Analysis, 5-Why, CAPA

Educational And Experience Requirements

Level of Education

• BE
• MBA

Experience

• 12 years
• 15 years