Sr. Manager – Machine Shop

Location: Daman

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/Hyper Mill/Power Mill), 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/GGG
40+), stainless; heat treatment interactions and distortion control.
Metrology: CMM, height gauges, bore gauges, profilometers, laser alignment, ball-bar.