Production Manager- Foundry

Kirloskar Brothers Limited; Satara, Sangli District; On-site; INR 3,000,000 - 4,200,000; Full time

Job summary

Kirloskar Brothers Limited in Satara, Maharashtra seeks a Senior Manager - Foundry Operations to oversee production planning, process control, and inventory management across shifts within a high-precision foundry environment.

The role emphasizes safety, 5S, TPM, cost control, and driving continuous improvement through effective planning and strong team leadership.

Responsibilities

• Plan and execute monthly, weekly, and daily production schedules from pattern receipt to casting pouring.
• Ensure heat-wise load balancing and timely mould readiness as per production priorities.
• Monitor production targets, productivity, and smooth operational flow across all shifts.
• Coordinate with PPC, melting, knockout, fettling, & heat treatment teams for uninterrupted production flow.
• Monitor casting tracking status and ensure smooth flow of all operations.

Job description

Summary / Purpose of the role

• The Senior Manager - Foundry Operations is responsible for overseeing process control, quality control, resource management, and ensuring smooth execution of operational processes. The role emphasizes maintaining safety, quality, and 5S standards, while driving quality and efficiency through effective planning and team management.

Key Responsibilities

1. Production Planning & Execution

• Plan and execute monthly, weekly, and daily production schedules from pattern receipt to casting pouring
• Ensure heat-wise load balancing and timely mould readiness as per production priorities.
• Monitor production targets, productivity, and smooth operational flow across all shifts.
• Coordinate with PPC, melting, knockout, fettling, & heat treatment teams for uninterrupted production flow.
• Monitor casting tracking status and ensure smooth flow of all operations.

2. Process Control & Quality Improvement

• Ensure adherence to standard process parameters, work instructions, and quality requirements.
• Drive reduction of casting rejection, rework, and process deviations through corrective actions.
• Monitor mould, core, and assembly quality to ensure dimensional and process accuracy.
• Coordinate with Quality department for defect analysis and implementation of preventive measures.
• Support continuous improvement initiatives for productivity, process stability, and quality enhancement.
• Ensure proper traceability and identification of moulds, cores, and castings.

3. SAP, Material & Inventory Control

• Ensure accurate SAP transactions related to casting movement, material consumption, and order status.
• Monitor logical and physical confirmation of castings and production materials.
• Conduct monthly physical and system stock verification of materials.
• Troubleshoot SAP transaction and casting confirmation related issues.
• Coordinate with stores and procurement for uninterrupted availability of consumables and materials.
• Ensure proper production records, reports, and inventory accuracy.

4. Team Management & Operational Coordination

• Manage manpower deployment, shift coordination, and workforce productivity.
• Coordinate with Pattern Shop for timely receipt, usage, and return of patterns and core boxes.
• Support training, skill development, and discipline within the production team.
• Ensure effective communication and execution of daily production priorities.

5. Safety, TPM & Cost Control

• Ensure compliance with safety standards, PPE usage, and safe working practices.
• Implement TPM, 5S, and housekeeping activities in production areas.
• Monitor and control production costs, material consumption, and process losses.
• Drive initiatives for productivity improvement, waste reduction, and operational efficiency.
• Ensure compliance with ISO procedures, audit requirements, and statutory guidelines.