Operations Head - Foundry

Mahindra And Mahindra Ltd.; Kalamba Mahali; On-site; INR 2,800,000 - 4,200,000; Full time

Job summary

Mahindra & Mahindra Ltd. in Maharashtra seeks a seasoned Grey Iron casting operations leader to drive plant performance, safety, and efficiency. You will oversee production planning, maintenance coordination, and manpower deployment to ensure reliable operations.

The role requires 15+ years in grey iron casting, with 5+ years in leadership, and a proven track record of managing complex manufacturing lines. Strong TPM, OEE improvement, and cost-reduction focus are essential.

Qualifications

• Graduate in Metallurgy/Mechanical Engineering/Foundry Technology.
• 15+ years in Grey Iron casting manufacturing with 5+ years in leadership.
• Experience in plant operations management including production planning, maintenance, and manpower deployment.

Responsibilities

• Improve Overall Equipment Effectiveness (OEE) and reduce downtime through TPM and preventive maintenance.
• Reduce casting rejection and rework by strengthening process controls at melting, molding, pouring and fettling stages.
• Achieve first-time-right casting rate >95% via audits and root cause analysis for defect resolution.
• Drive manufacturing cost reduction by optimizing raw material mix, yield and energy consumption.
• Develop future leaders by identifying high-potential employees and structured mentoring.

Education

Graduate in Metallurgy/Mechanical Engineering/Foundry Technology

Job description

Select how often (in days) to receive an alert:

• 1. Improve productivity by Improving plant capacity utilization to >90% & introducing skill-based training and work standardization.
• 2. To Reduce casting rejection & rework by strengthening process controls at melting, molding, pouring and fettling stages.
• 3. To Achieve first-time-right casting rate >95% by implementing process audits and root cause analysis for defect resolution.
• 4. To Achieve manufacturing cost reduction by optimizing raw material mix, yield improvement and energy consumption.
• 5. Reduce consumables & energy cost per ton by introducing efficiency monitoring and Material optimization programs.
• 6. Improve overall equipment effectiveness (OEE) by implementing TPM, preventive maintenance and breakdown analysis.
• 7. To Reduce cycle time & lead time by streamlining workflow from Melting to dispatch
• 8. To Achieve zero accidents by strict enforcement of safety SOPs, training & hazard audits.
• 9. To Ensure 100% statutory compliance by regular monitoring of environmental, safety and legal requirements.
• 10. To Improve shop-floor discipline & safety culture by ensuring daily toolbox talks and monthly safety reviews.
• 11. To Build high-performing manufacturing teams by continuous skill development and leadership coaching.
• 12. To Reduce attrition & absenteeism by improving engagement, communication and motivation programs.
• 13. To Develop future leaders by identifying high-potential employees and structured mentoring.
• 14. To Introduce new process technologies by benchmarking global foundry practices and implementing best practices.
• 15. To Improve plant competitiveness by driving innovation in casting Manufacturing, materials & automation.
• 16. To Achieve >98% equipment availability by strengthening preventive and predictive maintenance activities in coordination with Maintenance Team.
• 17. To Reduce unplanned downtime by implementing failure analysis in coordination with Maintenance Team.
• 18. Improve asset life & performance by introducing condition-based monitoring & modernization initiatives in coordination with Maintenance Team.

Preferred Industries

Education Qualification

Graduate in Metallurgy/Mechanical Engineering/Foundry Technology

General Experience

Critical Experience

• a. 15+ years of progressive experience in Grey Iron casting manufacturing, with at least 5+ years in leadership role.
• b. Proven track record of plant operations management, including production planning, maintenance coordination, and manpower deployment.

System Generated Core Skills

System Generated Secondary Skills

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