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
- Current 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

📌 HEAD OF MANUFACTURING (India)
🏢 Magnaplast Technologies (India) Private
📍 India