Head Of Manufacturing / Manufacturing Head

JOB DESCRIPTION – HEAD OF MANUFACTURING / MANUFACTURING Head

1. POSITION DETAILS

Designation: Head – Manufacturing

Department: Manufacturing & Operations

Reporting To: Managing Director / Director

Location: Pune, Maharashtra

Experience: 20+ Years – Mandatory

Education: B.E./B.Tech – Mechanical / Production / Polymer / Industrial Engineering; MBA/PGDM Operations preferred

Industry Preference: Manufacturing / Engineering / Automotive / Polymer / Industrial Products

Role Objective

To take complete ownership of the company's manufacturing operations and manufacturing P&L, ensuring profitable production, optimum capacity utilization, cost control, quality, delivery, productivity, manpower efficiency, maintenance, tooling, and continuous improvement.

The Manufacturing Head will function as a business leader, not only as a Production Head, and will report directly to the Director.

2. KEY RESPONSIBILITIES

A. Manufacturing & Operations

• Overall responsibility for all manufacturing activities, production lines, shifts, and shop-floor operations.
• Prepare and execute daily, weekly, and monthly production plans.
• Ensure ≥95% achievement of approved production plans.
• Optimize machine, manpower, material, and capacity utilization.
• Identify and remove production bottlenecks.
• Ensure timely production against customer commitments.
• Monitor production efficiency and process performance.
• Establish strong shop-floor discipline, 5S, safety, and operational standards.

Key KPI

• Production Plan Achievement
• Capacity Utilization
• Machine Utilization
• OEE
• Production Efficiency
• On-time Production
• Manpower Productivity

B. Manufacturing P&L & Cost Control

Directly responsible for understanding and improving the financial performance of manufacturing.

• Prepare/review monthly Manufacturing P&L.
• Analyse manufacturing cost vs. standard/budget.
• Review product-wise manufacturing contribution.
• Identify reasons for cost variance.
• Control:
• Raw material consumption
• Conversion cost
• Labour cost
• Power & energy cost
• Maintenance cost
• Tooling cost
• Scrap and rejection
• Rework
• Consumables
• Manufacturing overheads
• Work closely with Accounts & Finance for accurate cost allocation and profitability analysis.
• Implement annual cost-reduction targets.

Key KPI

• Manufacturing Contribution
• Conversion Cost / Unit
• Cost Reduction
• Material Yield
• Manufacturing P&L vs. Budget
• Power Cost / Unit
• Labour Cost / Unit

3. PRODUCTION, PLANNING & CAPACITY

• Prepare monthly and weekly capacity plans based on sales demand.
• Review machine-wise available capacity and utilization.
• Identify bottleneck machines/processes.
• Plan additional shifts, manpower, machines, and outsourcing where required.
• Ensure optimum utilization of existing capacity before recommending CAPEX.
• Prepare 3-year manufacturing capacity plans.
• Support management in business growth and expansion planning.

KPI

• Capacity Utilization
• Bottleneck Reduction
• Production Lead Time
• Machine Output
• Capacity vs. Demand

4. PRODUCTIVITY & CONTINUOUS IMPROVEMENT

Drive continuous improvement through:

• Lean Manufacturing
• TPM
• OEE
• Kaizen
• Six Sigma principles
• Process optimization
• Cycle-time reduction
• Changeover-time reduction
• Automation
• Layout improvement
• Material-flow improvement

KPI

• OEE Improvement
• Output / Machine
• Output / Employee
• Cycle-Time Reduction
• Changeover-Time Reduction
• Annual Cost Savings

5. QUALITY, SCRAP & REJECTION

• Coordinate with Quality for manufacturing-related quality issues.
• Identify root causes of rejection and rework.
• Implement corrective and preventive actions.
• Monitor process capability and first-pass yield.
• Establish process controls.
• Monitor customer complaints related to manufacturing.
• Control and reduce scrap generation.
• Analyse scrap value and recovery opportunities.

KPI

• Internal Rejection %
• Rework %
• Scrap %
• First Pass Yield
• Customer Complaints
• Cost of Poor Quality

6. MAINTENANCE & TOOLING

Maintenance

• Ensure preventive and predictive maintenance.
• Monitor machine breakdown and downtime.
• Identify recurring breakdowns.
• Ensure critical spare availability.
• Improve machine availability and reliability.

Tooling

• Ensure production tool availability.
• Monitor tool life and maintenance.
• Coordinate new tool development and modifications.
• Reduce tool-related production downtime.
• Maintain critical tools/spares for emergency requirements.

KPI

• Machine Availability
• Breakdown Hours
• Preventive Maintenance Compliance
• Tool Life
• Tool-related Downtime
• Maintenance Cost

7. NEW PRODUCT & PROCESS INDUSTRIALIZATION

Work closely with R&D, Sales, Quality, Tooling, and Purchase for new products.

Responsibilities include:

• Manufacturing feasibility
• Process development
• Machine requirement
• Tooling requirement
• Cycle-time estimation
• Manufacturing cost
• Trial planning
• Process validation
• Production transfer
• Mass-production readiness

KPI

• On-time Industrialization
• Trial Success Rate
• Target Manufacturing Cost
• Development-to-Production Lead Time

8. MANPOWER & TEAM MANAGEMENT

• Lead the complete manufacturing organization.
• Establish clear responsibilities and KPIs.
• Optimize manpower deployment.
• Control overtime.
• Develop multi-skilled operators.
• Identify training requirements.
• Build second-line leadership.
• Conduct daily, weekly, and monthly performance reviews.
• Create accountability at every level.

KPI

• Output / Employee
• Labour Cost / Unit
• Overtime %
• Absenteeism
• Multi-skilled Manpower %
• Team KPI Achievement

9. CAPEX & INVESTMENT MANAGEMENT

• Identify machine and technology requirements.
• Prepare CAPEX proposals.
• Evaluate technical and financial feasibility.
• Calculate expected ROI / payback.
• Ensure proper utilization of approved CAPEX.
• Track project implementation and benefits after commissioning.
• Recommend automation and technology upgrades where financially justified.

KPI

• CAPEX vs. Budget
• ROI / Payback
• Project Completion
• Capacity Addition
• Productivity Improvement

10. ERP, MIS & REPORTING

Ensure accurate manufacturing data in ERP and management reports.

Daily Report

• Production Plan vs. Actual
• Machine-wise Production
• Downtime
• Rejection
• Scrap
• Manpower
• Material Shortage
• Critical Orders
• Action Points

Weekly Report

• Production Performance
• Capacity Utilization
• OEE
• Rejection & Scrap
• Maintenance
• Productivity
• Cost Variance
• Pending Actions

Monthly Management Report

• Manufacturing P&L
• Product-wise Manufacturing Cost
• Manufacturing Contribution
• Production Achievement
• Capacity Utilization
• OEE
• Scrap & Rejection
• Labour Productivity
• Machine Downtime
• Maintenance Cost
• Energy Cost
• Cost Reduction
• CAPEX
• Major Risks & Corrective Actions

11. STRATEGIC RESPONSIBILITIES

The Manufacturing Head will participate directly in management-level decisions related to:

• Manufacturing strategy
• Capacity expansion
• New machines
• Automation
• Plant layout
• Make vs. Buy
• Outsourcing
• Cost reduction
• New product industrialization
• Manufacturing technology
• Productivity improvement
• Workforce planning
• Annual manufacturing budget
• 3-year manufacturing roadmap

12. REQUIRED EXPERIENCE & PROFILE

Mandatory

• 20+ years of manufacturing experience.
• Minimum 5–10 years in Plant Head / Manufacturing Head / Operations Head / Factory Head / senior manufacturing leadership.
• Proven experience managing complete manufacturing operations.
• Experience managing large teams and multiple production processes.
• Experience in manufacturing cost control and P&L analysis.
• Experience in capacity planning and CAPEX.
• Proven record of productivity and cost improvement.
• Strong shop-floor and business management experience.

Preferred

Experience in:

• Automotive / Engineering Manufacturing
• Polymer / Magnet / Industrial Products
• Extrusion / Injection Moulding / Processing
• Multiple-shift manufacturing
• ERP / MRP
• Lean / TPM / OEE
• Automation
• New Product Industrialization
• ISO / Quality systems

13. REQUIRED SKILLS

Technical

• Production Management
• Manufacturing Engineering
• Production Planning
• Capacity Planning
• Manufacturing Costing
• P&L Analysis
• Lean Manufacturing
• TPM / OEE
• Quality & Process Control
• Maintenance
• Tooling
• CAPEX
• ERP / MRP
• Inventory & Material Management
• Safety & 5S

Leadership

• Strong ownership and accountability
• Business-oriented mindset
• Analytical decision-making
• Problem-solving
• Cost-conscious approach
• Strong team leadership
• Ability to work directly with promoters/directors
• Ability to take quick decisions under pressure
• Strong communication and negotiation
• High integrity and discipline

14. KEY PERFORMANCE INDICATORS – MANAGEMENT SCORECARD

KPI Area

Key Measure

Production

≥95% Plan Achievement

Capacity

Optimum Utilization

OEE

Continuous Improvement

P&L

Monthly Manufacturing P&L

Cost

Conversion Cost Reduction

Material

Yield Improvement

Scrap

Continuous Reduction

Rejection

Continuous Reduction

Quality

FPY / Customer Complaints

Maintenance

Machine Availability

Downtime

Continuous Reduction

Labour

Output / Employee

Energy

Cost / Unit

Tooling

Tool-related Downtime

CAPEX

ROI & Payback

Delivery

Production On-time

NPD

On-time Industrialization

Cost Saving

Annual Target Achievement

Team

Department KPI Achievement

15. OVERALL SUCCESS EXPECTATION

The Manufacturing Head will be successful when the company achieves:

Higher Production + Higher Capacity Utilization + Lower Manufacturing Cost + Lower Scrap/Rejection + Higher Productivity + Better Quality + Better Delivery + Stronger Manufacturing P&L.

The person must be capable of answering management at any time:

• What is our manufacturing cost?
• Where are we losing money?
• Which products/processes are most profitable?
• What is our available capacity?
• Why is production behind plan?
• What is the cost of downtime?
• How much scrap are we generating and why?
• How can we reduce manufacturing cost?
• What CAPEX is required and what ROI will it generate?
• What action will improve manufacturing profitability next month?

FINAL ACCOUNTABILITY

Manufacturing Head = Production + Quality + Cost + Productivity + Capacity + Maintenance + Tooling + People + Manufacturing P&L + Continuous Improvement

Experience: 20+ Years | Reporting: Directly to Managing Director / Director | Primary Accountability: Profitable Manufacturing Operations