Job Purpose
Lead and manage the overall operations of New High Tech Manufacturing Plant, ensuring safe, efficient, and cost-effective production of door handles and related hardware products while achieving production, quality, delivery, productivity, and cost targets.
The role will oversee the end-to-end manufacturing operations, including production, metal melting/casting processes, finishing operations, quality, maintenance, manpower, productivity, and continuous improvement.
Key Responsibilities
1. Plant Operations & Production
- Lead the overall day-to-day operations of the manufacturing plant.
- Develop and execute production plans in line with business demand and delivery requirements.
- Ensure achievement of production targets, capacity utilization, productivity, and OEE.
- Monitor production performance and identify bottlenecks and improvement opportunities.
- Ensure efficient utilization of manpower, machines, materials, and production resources.
- Establish and maintain effective production standards and operating procedures.
2. Metal Melting & Casting Operations
- Oversee and optimize metal melting and casting operations and ensure compliance with approved process parameters.
- Ensure efficient utilization of raw materials and control material losses, scrap, and yield.
- Monitor melting/casting productivity, quality, energy consumption, and process efficiency.
- Work closely with Engineering and Quality teams to resolve casting defects and improve process stability.
- Ensure proper handling and control of metals, alloys, molds/dies, and related production materials.
3. Door Handles / Hardware Manufacturing
- Lead manufacturing operations related to door handles and architectural hardware.
- Ensure understanding and control of the complete manufacturing flow, from raw material processing through casting, machining, polishing/finishing, assembly, and final inspection.
- Drive improvements in product quality, dimensional accuracy, appearance, and finishing quality.
- Ensure production processes are aligned with customer and product specifications.
4. Quality Management
- Ensure consistent achievement of product quality standards.
- Monitor production defects, rejection, rework, scrap, and customer complaints.
- Lead root-cause analysis and corrective/preventive actions.
- Partner with Quality to establish process controls and reduce defects.
5. Maintenance & Equipment Reliability
- Ensure high availability and reliability of production equipment.
- Work closely with Maintenance to establish preventive and predictive maintenance plans.
- Monitor machine downtime, breakdowns, MTBF, and MTTR.
- Support CAPEX and equipment-upgrade initiatives.
6. Cost & Productivity
- Control manufacturing costs and improve overall plant profitability.
- Monitor material consumption, scrap, energy consumption, overtime, and labor productivity.
- Identify and implement cost-saving and waste-reduction initiatives.
- Drive Lean Manufacturing and continuous improvement initiatives.
7. People & Workforce Management
- Lead and develop the plant's production and operational teams.
- Ensure appropriate manpower planning based on production requirements.
- Establish clear performance expectations and KPIs.
- Build a culture of accountability, safety, quality, and continuous improvement.
8. Health, Safety & Compliance
- Ensure full compliance with HSE requirements and company policies.
- Promote a strong safety culture across all plant operations.
- Ensure compliance with applicable regulatory and environmental requirements.
9. Continuous Improvement
- Lead initiatives to improve productivity, process efficiency, yield, quality, and manufacturing lead time.
- Apply Lean Manufacturing, Kaizen, 5S, root-cause analysis, and other operational excellence methodologies.
- Establish and monitor plant-level operational KPIs.
Qualifications
- Bachelor's degree in Mechanical / Production / Industrial Engineering or a related engineering discipline.
- 10–15+ years of relevant manufacturing experience, with significant experience in plant/production management.
- Strong hands-on experience in metal melting and casting processes is highly preferred.
- Experience in door handles, architectural hardware, sanitary hardware, home appliances, automotive components, or other metal-based manufacturing industries is highly preferred.
- Experience with casting, machining, polishing, plating/coating, finishing, and assembly operations is a strong advantage.
- Strong understanding of production planning, quality, maintenance, cost control, and operational excellence.
- Experience managing plant KPIs such as OEE, yield, scrap, rejection, productivity, downtime, and OTIF.
- Strong leadership, problem-solving, analytical, and decision-making skills.
- Good command of English and strong MS Office skills.
