Website:
menschen.co.in
Job details:
Sr. Manager – Machine Shop (Kachigam)
Role Purpose Own end-to-end performance of the Machine Shop at Kachigam—people, process, and productivity. Lead multi-shift operations across CNC/VMCs, HMCs, turning, grinding, and tool-room; ensure right-first-time quality, on-time delivery to assembly, and continuous improvement aligned to business goals.
Reporting
- Reports to: Head – Operations (Plant)
- Leads: 60–120 associates across supervisors, CNC programmers, machinists, inspectors, tool crib, planning, and maintenance liaison
Key Responsibilities
- Safety, Health, Environment
- Champion a zero-harm culture; conduct daily Gemba safety walks, near-miss tracking, and corrective actions.
- Ensure compliance with PPE, LOTO, SPCC/waste oil handling, 5S, and statutory audits.
- People and Leadership
- Build capability: skill-matrix, cross-training, certification on CNC, setup, inspection.
- Workforce planning, shift scheduling, mentoring of supervisors; drive engagement and retention.
- Production Execution
- Translate MPS/weekly plans into cell-level schedules; balance load across machines and shifts.
- Ensure adherence to cycle times, changeover targets, and material/tool availability.
- Quality Assurance
- Enforce first-off and in-process inspection; approve FAIRs for new parts.
- Contain and root-cause nonconformities (8D/5-Why), reduce rework/scrap; collaborate with QA and Design for drawing clarifications.
- Technical Excellence
- Oversee CNC programming standards (Fanuc/Siemens/Heidenhain), toolpath optimization, and DFM feedback to Engineering.
- Approve complex setups, jigs/fixtures, and special tooling; validate capability (Cp/Cpk) for critical features.
- Maintenance and Asset Care
- Coordinate with maintenance for preventive/predictive maintenance; drive OEE and MTBF improvements.
- Plan machine calibration, leveling, ball-bar/laser checks, and spares criticality.
- Materials, Tooling, and Cost
- Control cutting tool consumption, regrind cycles, and standardization.
- Optimize raw material utilization, nesting, and offcut management; reduce outsourced machining cost through make/buy analytics.
- Continuous Improvement (Lean/TPM)
- Lead Kaizens, SMED for changeovers, line balancing, 5S audits, and visual management.
- Deploy standard work, mistake-proofing, and closed-loop parameter control on critical processes.
- New Product Introduction (NPI)
- Industrialize new parts: process sheets, setup sheets, PFMEA, control plans; achieve PPAP where applicable.
- Pilot runs to rate production, stabilize cycle times, and handover to steady state.
Functional Competencies
- CNC Manufacturing
- Advanced CNC programming and optimization (turning, milling, 4/5-axis preferred); G/M code literacy.
- Fixture design principles, clamping, datum strategy, and thermal stability.
- Cutting tool technology (carbide/CBN/PCD), speeds/feeds, MQL/coolant management.
- Process Engineering and Quality
- Process planning: routing, time study, process sheets, control plans.
- GD&T, precision metrology (CMM/program review, surface finish, concentricity, runout).
- PFMEA, SPC, MSA, and statistical problem-solving.
- Operations and Planning
- Capacity modeling, S&OP handshakes, finite scheduling, and dispatching.
- OEE analytics, bottleneck management, and TOC concepts.
- Lean/TPM/Digital
- 5S, Kaizen, SMED, value stream mapping; autonomous and planned maintenance pillars.
- Exposure to shop-floor digitalization: DNC, NC program control, OEE systems, e-Kanban, tool vending, QR-based traceability.
- Compliance and EHS
- Knowledge of Indian factory regulations, hazardous waste handling, and safe lifting/rigging practices.
Leadership Behaviors
- Owner mindset; data-driven with strong floor presence.
- Clear communicator; coaches supervisors; manages conflict constructively.
- Bias for action with disciplined follow-through.
- Collaborative with Design, Sourcing, QA, Planning, and Assembly.
- Customer-back thinking—internal customer (assembly/test) first.
Qualifications and Experience
- Education: BE/BTech/Diploma in Mechanical/Production/Manufacturing (or equivalent).
- Experience: 12–18 years in precision machining with at least 4–6 years leading multi-shift machine shop operations.
- Tools/Systems: Hands-on with CNC programming; exposure to CAM (e.g., Mastercam/HyperMill/PowerMill), ERP (SAP/Oracle/Microsoft Dynamics), and OEE/Andon.
- Desirable: Experience in capital equipment/heavy engineered parts; knowledge of extrusion machinery parts; certification in Lean/TPM/Six Sigma (Green/Black Belt); AutoCAD/3D CAD literacy for drawing interpretation.
Tools, Machines, and Materials Exposure
- VMC/HMC/turning centers (Fanuc/Siemens/Heidenhain), grinding (cylindrical/surface), gear hobbing/shaping (nice to have), deep-hole drilling.
- Materials: alloy steels, tool steels, aluminum, cast iron (GG25/GGG40+), stainless; heat treatment interactions and distortion control.
- Metrology: CMM, height gauges, bore gauges, profilometers, laser alignment, ball-bar.
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