Position Title: Forging Plant Head.
Location: Hyderabad, Pashamylaram.
Department: Operations/Manufacturing
Reports To: Operations Head

Job Summary:
The Forging Plant Head is responsible for overseeing and managing all aspects of the forging plant operations, including hot forging, cold forging, open-die forging, closed-die forging, and seamless rolled ring forging. This includes production planning, quality control, maintenance, safety, and workforce management. The role requires strong leadership skills, extensive knowledge of forging processes, and the ability to drive continuous improvement to achieve operational excellence.

Key Responsibilities:

1. Operational Management:
• Oversee daily operations of the forging plant, including hot forging, cold forging, and precision forging processes to ensure efficiency and productivity.
• Develop and implement production schedules using Advanced Planning and Scheduling (APS) systems to meet delivery deadlines and customer requirements.
• Monitor and optimize the use of resources, including raw materials, forging lubricants, and billet heating furnaces.
• Ensure the efficient use of induction heating and controlled atmosphere furnaces for billet heating.

2. Quality Control:
• Ensure adherence to quality standards and specifications, such as ISO 9001, AS9100, and IATF 16949.
• Implement and maintain Statistical Process Control (SPC) systems to detect and address defects and non-conformities.
• Work closely with the quality assurance team to conduct regular inspections, including non-destructive testing (NDT), ultrasonic testing (UT), magnetic particle inspection (MPI), and dye penetrant inspection (DPI).
• Utilize Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) software for die design and simulation to ensure precision and accuracy.

3. Safety and Compliance:
• Promote a culture of safety and ensure compliance with OSHA regulations and environmental standards.
• Conduct regular safety training and Hazard and Operability Study (HAZOP) assessments for employees.
• Address any safety incidents promptly and implement corrective actions using Root Cause Analysis (RCA).
• Ensure compliance with Occupational Health and Safety Management Systems (OHSMS).

4. Maintenance and Equipment:
• Oversee the maintenance and repair of forging equipment, such as hydraulic presses, mechanical presses, induction heaters, and forging hammers.
• Develop and implement predictive maintenance programs using Condition Monitoring (CM) techniques to minimize downtime.
• Coordinate with the maintenance team to ensure the availability of spare parts, including die sets, forging rolls, and tooling.
• Implement and manage Computerized Maintenance Management Systems (CMMS) to track maintenance activities and equipment performance.

5. Continuous Improvement:
• Identify opportunities for process improvement and implement Lean Six Sigma methodologies.
• Lead initiatives to enhance productivity, reduce waste, and lower operational costs through Value Stream Mapping (VSM) and Kaizen events.
• Stay updated with the latest technologies and advancements in forging processes, including automation, robotics, and Industry 4.0 applications.
• Implement advanced forging simulation software to optimize forging processes and reduce trial-and-error in die design.

6. Team Management:
• Supervise and mentor plant staff, including production workers, supervisors, and support staff, ensuring adherence to Standard Operating Procedures (SOPs) and Work Instructions (WIs).
• Conduct performance evaluations and provide feedback and training as needed.
• Foster a collaborative and positive work environment, encouraging teamwork and cross-functional collaboration.
• Develop training programs for new technologies and processes, ensuring continuous skill enhancement of the workforce.

7. Budgeting and Cost Control:
• Develop and manage the plant’s budget, ensuring cost-effective operations and adherence to financial targets.
• Monitor expenses and implement cost-saving measures, such as energy management and waste reduction initiatives, without compromising quality.
• Prepare regular financial and operational reports for senior management, including Key Performance Indicators (KPIs) and Operational Efficiency Metrics.

Qualifications:

• Education: Bachelor’s degree in Mechanical Engineering, Metallurgical Engineering, Industrial Engineering, or a related field
• Experience: Minimum of 10-15 years of experience in a manufacturing environment (Forging) , with at least 5-7 years in a supervisory or managerial role within a forging plant.
• Technical Skills:
o In-depth knowledge of forging processes, metallurgy, thermomechanical processing, and heat treatment.
o Proficiency in using manufacturing software and Enterprise Resource Planning (ERP) systems, such as SAP or Oracle.
o Understanding of Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) for die and tooling design.
o Familiarity with Statistical Process Control (SPC), Six Sigma, and Lean manufacturing principles.
o Knowledge of non-destructive testing methods, including ultrasonic testing (UT), magnetic particle inspection (MPI), and dye penetrant inspection (DPI).
• Leadership Skills:
o Strong leadership and team management skills. Ability to motivate and lead a diverse workforce.
• Problem-Solving:
o Excellent problem-solving and decision-making abilities. Ability to handle complex and challenging situations using data-driven approaches.
• Communication:
o Strong verbal and written communication skills. Ability to interact effectively with all levels of the organization and external stakeholders.
• Safety Orientation:
o Commitment to maintaining a safe work environment and ensuring compliance with safety regulations and standards.

Additional Requirements:

• Ability to work in a fast-paced and dynamic environment.
• Flexibility to work extended hours and weekends as needed.
• Strong organizational and time management skills.

Benefits:

• Competitive salary and performance-based incentives.
• Comprehensive health and wellness benefits.
• Opportunities for professional development and career advancement.
• A supportive and collaborative work environment.