Plant Operations

Amor Management Consultants; Pune District; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

Amor Management Consultants seeks an experienced Plant Operations Lead for an Aluminium Gravity Die Casting facility in Aurangabad. You will manage day-to-day operations, plan production targets, and ensure safety and quality adherence.

The role requires 12+ years in manufacturing, strong GDC knowledge, team leadership, and a track record of improving OEE, cycle times, and cost efficiency through Lean methods.

Qualifications

• 12 -20 years of experience in manufacturing/plant operations, preferably in Aluminium Gravity Die Casting.
• Strong experience in handling GDC production and plant operations.
• Hands-on exposure to aluminium melting, gravity die casting processes, die handling and casting defect analysis.
• Experience managing production teams and achieving production, quality, cost and delivery targets.
• Exposure to OEE, TPM, Lean Manufacturing, Kaizen and continuous improvement.
• Experience in automotive component manufacturing will be preferred.

Responsibilities

• Manage day-to-day Gravity Die Casting plant operations and ensure smooth production activities.
• Plan and achieve production targets in line with customer requirements and delivery schedules.
• Handle GDC machines, melting furnaces, holding furnaces, dies, trimming and related casting equipment.
• Monitor critical casting parameters such as metal temperature, die temperature, pouring parameters, cycle time, filling, solidification and cooling conditions.
• Ensure optimum utilization of machines, manpower, dies, equipment, and other production resources.
• Monitor OEE, productivity, rejection, rework, downtime, cycle time and overall equipment utilization.

Skills

GDC production

Aluminium gravity die casting

Plant operations

Team management

OEE TPM Kaizen

Education

BE/B.Tech/Diploma in Mechanical / Production / Metallurgy / Manufacturing Engineering or equivalent

Job description

Plant Operations

Exp: 12+ years

Location : Aurangabad.

Job Description

• Manage day-to-day Gravity Die Casting plant operations and ensure smooth production activities.
• Plan and achieve production targets in line with customer requirements and delivery schedules.
• Handle GDC machines, melting furnaces, holding furnaces, dies, trimming and related casting equipment.
• Monitor critical casting parameters such as metal temperature, die temperature, pouring parameters, cycle time, filling, solidification and cooling conditions.
• Ensure optimum utilization of machines, manpower, dies, equipment, and other production resources.
• Monitor OEE, productivity, rejection, rework, downtime, cycle time and overall equipment utilization.
• Drive reduction of casting defects such as porosity, shrinkage, cold shut, misrun, blow holes, inclusions and dimensional issues.
• Work closely with Quality and Process Engineering teams for root-cause analysis and corrective/preventive actions.
• Coordinate with Maintenance for preventive maintenance, breakdown reduction, machine availability, and utility requirements.
• Ensure proper die changeover, die maintenance, die life monitoring and process setup.
• Control manufacturing costs through reduction of scrap, rejection, energy consumption, consumables and manpower cost.
• Implement Lean Manufacturing, Kaizen, 5S, TPM, OEE and continuous improvement initiatives.
• Develop and monitor production KPIs and prepare periodic performance reports for management.
• Lead and develop production teams, including supervisors, engineers, operators and contract manpower.
• Ensure adherence to SOPs, work instructions, process standards and safety procedures.
• Maintain compliance with quality, safety and environmental requirements.
• Coordinate with PPC/Planning, Purchase, Stores and Dispatch to ensure uninterrupted production and timely customer deliveries.
• Participate in new product development, process trials, line trials and capacity enhancement projects.
• Support customer and internal audits and ensure timely closure of audit observations.
• Identify opportunities for capacity improvement, automation, process optimization and productivity enhancement.

Required Experience

• 12 -20 years of experience in manufacturing/plant operations, preferably in Aluminium Gravity Die Casting.
• Strong experience in handling GDC production and plant operations.
• Hands-on exposure to aluminium melting, gravity die casting processes, die handling and casting defect analysis.
• Experience managing production teams and achieving production, quality, cost and delivery targets.
• Exposure to OEE, TPM, Lean Manufacturing, Kaizen and continuous improvement.
• Experience in automotive component manufacturing will be preferred.

Educational Qualification

B.E./B.Tech/Diploma in Mechanical / Production / Metallurgy / Manufacturing Engineering or equivalent.