Plant Manufacturing Head

Madras Engineering Industries PVT LTD; Chennai District; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

Madras Engineering Industries Pvt Ltd in India seeks a senior plant leader to drive end-to-end operations for precision automotive components. You will oversee production, quality, maintenance, PPC, process engineering, stores and EHS to hit targets on time, quality and cost.

The role requires 25+ years in automotive components and 5+ years in a leadership capacity, with hands-on CNC, VMC/HMC, SPM and lean manufacturing expertise.

Qualifications

• BE/B.Tech in Mechanical/Production/Automobile Engineering.
• 25+ years in automotive component manufacturing; 5+ years in a plant leadership role.

Responsibilities

• Lead Production, Quality, Maintenance, PPC, Process Engineering, Stores and EHS functions.
• Achieve production, productivity, quality, delivery and cost targets.
• Provide technical leadership for CNC turning, VMC, HMC, SPM and grinding operations.
• Improve cycle time, tool life, machine utilisation, process capability and OEE.
• Resolve machining issues involving dimensional variation, tool failure, chatter, rejection and process instability.
• Review machining parameters, CNC programs, cutting tools, fixtures, layouts and capacity requirements.
• Drive preventive and predictive maintenance; improve MTBF and MTTR.
• Ensure compliance with IATF 16949 and customer-specific requirements.
• Lead APQP, PPAP, PFMEA, Control Plan, SPC, MSA, RCA and CAPA activities.
• Reduce rejection, rework, scrap, customer complaints and conversion costs.
• Manage plant budgets, CAPEX, inventory and cost-reduction initiatives.
• Lead new product industrialisation, machine commissioning and production ramp-up.
• Implement Lean Manufacturing, TPM, Kaizen, Poka-Yoke and SMED.
• Ensure compliance with safety, environmental, factory and statutory requirements.
• Develop functional heads and build a performance-driven plant team.
• Maintain effective employee relations and shop-floor discipline.

Skills

Leadership

CNC programming

GD&T

OEE/TPM/Lean

Quality audits

Decision making

Education

BE/B.Tech Mechanical/Production/Automobile

Tools

CNC turning

VMC

HMC

SPM

Grinding operations

Job description

Purpose of the Role

To lead end-to-end plant operations and achieve production, quality, delivery, cost, safety and profitability targets. The position requires extensive hands-on knowledge of precision machining and high-volume automotive component manufacturing.

Qualification:

B.E./B.Tech – Mechanical/Production/Automobile Engineering

Experience:

25+ years in automotive component manufacturing, including 5+ years in a plant leadership role.

Preferred Industry Background:

Automotive component manufacturers engaged in precision-machined products such as brake components, axle components, transmission parts, steering parts, suspension parts or other safety-critical components.

Key Responsibilities

• Lead Production, Quality, Maintenance, PPC, Process Engineering, Stores and EHS functions.
• Achieve production, productivity, quality, delivery and cost targets.
• Provide technical leadership for CNC turning, VMC, HMC, SPM and grinding operations.
• Improve cycle time, tool life, machine utilisation, process capability and OEE.
• Resolve machining issues involving dimensional variation, tool failure, chatter, rejection and process instability.
• Review machining parameters, CNC programs, cutting tools, fixtures, layouts and capacity requirements.
• Drive preventive and predictive maintenance; improve MTBF and MTTR.
• Ensure compliance with IATF 16949 and customer-specific requirements.
• Lead APQP, PPAP, PFMEA, Control Plan, SPC, MSA, RCA and CAPA activities.
• Reduce rejection, rework, scrap, customer complaints and conversion costs.
• Manage plant budgets, CAPEX, inventory and cost-reduction initiatives.
• Lead new product industrialisation, machine commissioning and production ramp-up.
• Implement Lean Manufacturing, TPM, Kaizen, Poka-Yoke and SMED.
• Ensure compliance with safety, environmental, factory and statutory requirements.
• Develop functional heads and build a performance-driven plant team.
• Maintain effective employee relations and shop-floor discipline.

Required Competencies

• Extensive knowledge of precision machining processes.
• Strong expertise in CNC/VMC/HMC programming, tooling, fixtures and GD&T.
• Knowledge of metallurgy, heat treatment and engineering drawings.
• Strong understanding of OEE, TPM, Lean Manufacturing and cost optimisation.
• Knowledge of IATF 16949 and automotive quality core tools.
• Experience handling automotive OEM customers and audits.
• Strong leadership, analytical, commercial and decision-making skills.

Key Performance Indicators

• Production plan achievement.
• On-time delivery.
• OEE and capacity utilisation.
• Productivity and conversion cost.
• Customer PPM and complaints.
• Internal rejection, rework and scrap.
• Machine breakdown, MTBF and MTTR.
• Safety and statutory compliance.
• Inventory and working-capital control.
• Employee productivity and development.