Operations Head - Foundry

Responsibilities & Key Deliverables

1.    Improve productivity by Improving plant capacity utilization to >90% & introducing skill-based training and work standardization.
2.    To Reduce casting rejection & rework by strengthening process controls at melting, molding, pouring and fettling stages.
3.    To Achieve first-time-right casting rate >95% by implementing process audits and root cause analysis for defect resolution.
4.    To Achieve manufacturing cost reduction by optimizing raw material mix, yield improvement and energy consumption.
5.    Reduce consumables & energy cost per ton by introducing efficiency monitoring and Material optimization programs.
6.    Improve overall equipment effectiveness (OEE) by implementing TPM, preventive maintenance and breakdown analysis.
7.    To Reduce cycle time & lead time by streamlining workflow from Melting to dispatch
8.    To Achieve zero accidents by strict enforcement of safety SOPs, training & hazard audits.
9.    To Ensure 100% statutory compliance by regular monitoring of environmental, safety and legal requirements.
10.    To Improve shop-floor discipline & safety culture by ensuring daily toolbox talks and monthly safety reviews.
11.    To Build high-performing manufacturing teams by continuous skill development and leadership coaching.
12.    To Reduce attrition & absenteeism by improving engagement, communication and motivation programs.
13.    To Develop future leaders by identifying high-potential employees and structured mentoring.
14.    To Introduce new process technologies by benchmarking global foundry practices and implementing best practices.
15.    To Improve plant competitiveness by driving innovation in casting Manufacturing, materials & automation.
16.    To Achieve >98% equipment availability by strengthening preventive and predictive maintenance activities in coordination with Maintenance Team.
17.    To Reduce unplanned downtime by implementing failure analysis in coordination with Maintenance Team.
18.    Improve asset life & performance by introducing condition-based monitoring & modernization initiatives in coordination with Maintenance Team.

Preferred Industries

Education Qualification

 Graduate in Metallurgy/Mechanical Engineering/Foundry Technology 

General Experience

Critical Experience

a.    15+ years of progressive experience in Grey Iron casting manufacturing, with at least 5+ years in leadership role. 
b.    Proven track record of plant operations management, including production planning, maintenance coordination, and manpower deployment.

System Generated Core Skills

System Generated Secondary Skills