Sr Manager-Operations

ROLE PURPOSE The Senior Manager Operations is a critical plant-level leadership role responsible for managing end-to-end production operations across Alicon's aluminium casting and machining value chain. The incumbent will oversee casting (Gravity Die Casting / LPDC / Sand Casting), machining, assembly, and dispatch — ensuring that world-class components are delivered to OEM customers with uncompromising quality, on-time delivery, and cost efficiency. This role demands deep technical knowledge of aluminium casting processes, strong operational discipline, and the ability to lead large shop floor teams in a high-volume, multi-product, OEM-driven environment.

KEY RESPONSIBILITIES

1. Production Planning & Shop Floor Management

• Manage day-to-day production operations across casting, heat treatment, machining, assembly, and despatch
• Translate customer schedules (OEM pull plans) into daily / shift-wise production targets and ensure achievement
• Drive shift utilization, machine loading, and operator deployment for optimal throughput
• Monitor WIP levels and ensure one-piece-flow discipline to detect and correct defects early in the process
• Coordinate with PPC and Supply Chain for raw material readiness, alloy availability, and dispatch schedules
• Manage production for Alicon's high-mix product portfolio: cylinder heads, engine brackets, intake manifolds, swing arms, CAC tanks, crankcases, and structural castings

2. Process Control & Quality Assurance

• Ensure adherence to casting process parameters for GDC, LPDC, and sand casting operations
• Implement and monitor Statistical Process Control (SPC) for critical casting and machining parameters
• Drive first-pass yield improvement and systematic reduction of porosity, shrinkage, cold shut, and other casting defects
• Coordinate with Quality team to address OEM customer complaints, PPAP requirements, and 8D / CAPA submissions
• Ensure adherence to IATF 16949, ISO 9001, and OEM-specific quality systems at the plant
• Monitor rejection and rework rates and drive root cause analysis and corrective actions

3. OEE & Productivity Improvement

• Drive improvement in Overall Equipment Effectiveness (OEE) across casting machines and CNC machining centres
• Identify and eliminate the six big losses: breakdowns, setup losses, idling, reduced speed, defects, and start-up losses
• Lead SMED initiatives to reduce die change and setup time across casting and machining operations
• Drive Lean Manufacturing, Kaizen, and 5S initiatives on the shop floor
• Implement cycle time reduction and throughput improvement projects

4. Cost Management & Profitability

• Control conversion cost per kg / per part through systematic productivity and yield improvement
• Manage alloy consumption, scrap rate, and melt loss — critical cost drivers in aluminium casting
• Monitor tooling, consumable, and energy costs and drive reduction initiatives
• Participate in cost estimation for new products during NPI / APQP stage
• Prepare and track monthly operational budgets vs actuals; report variances with corrective actions

5. Maintenance & Equipment Reliability

• Ensure Preventive Maintenance (PM) and Predictive Maintenance schedules are implemented for casting machines, furnaces, heat treatment equipment, and CNC machining centres
• Monitor machine uptime and MTBF / MTTR metrics; drive improvement plans
• Coordinate with Maintenance team for breakdown response and restoration within defined MTTR targets
• Oversee die / mould maintenance coordination to ensure tooling readiness

6. New Product Introduction (NPI) & Process Development

• Support APQP process for new component launches — from trial casting to PPAP approval
• Define process parameters, tooling requirements, and control plans for new products
• Work with the Technology / R&D team on process improvements and LPDC transition projects
• Participate in DFM (Design for Manufacturability) reviews with customers and the engineering team

7. Safety, Compliance & Environment

• Ensure safe working conditions on the shop floor — molten metal safety, PPE compliance, ergonomics, and fire prevention
• Drive zero-accident culture; investigate near-misses and implement corrective actions
• Ensure compliance with Factories Act requirements, environmental norms, and statutory obligations at the plant
• Drive energy conservation and waste reduction