Role Objective:

To lead and manage manufacturing operations across multiple plants and business verticals, with a strong focus on high-precision plastic components plastic parts manufactured with very tight dimensional and performance tolerances. The role will ensure consistent achievement of production, quality, cost, delivery, productivity and safety targets, while driving operational excellence, process standardization, capacity utilization and continuous improvement to build a scalable, high-performance and globally competitive manufacturing organization.

Role & responsibilities

1. Multi-Plant Operations

- Lead day-to-day manufacturing operations across multiple plants/business units.
- Drive plant-wise production, quality, cost and delivery performance.
- Establish common operating standards and best practices across plants.
- Conduct regular operational reviews with Plant Heads.

2. Production & Delivery

- Ensure achievement of production plans and customer delivery commitments.
- Optimize manpower, machines, shifts and production capacity.
- Resolve bottlenecks and improve throughput.
- Ensure effective coordination between Production, PPC, Quality, Maintenance and Supply Chain.

3. Productivity & OEE

- Drive improvement in OEE, machine utilization, labour productivity and cycle time.
- Reduce downtime, changeover time, rejection, rework and scrap.
- Implement Lean Manufacturing, TPM, Kaizen and other productivity initiatives.

4. Quality & Process Control

- Ensure consistent product and process quality across all manufacturing locations.
- Drive reduction in internal rejection, customer complaints and process variation.
- Strengthen process discipline, standard work and corrective-action systems.
- Partner with Quality to achieve customer-specific quality requirements.

5.



Cost Management

- Own manufacturing conversion cost and operational efficiency.
- Drive reduction in material wastage, labour cost, energy cost and manufacturing overheads.
- Identify and implement cost-saving opportunities across plants.

6. Capacity & Resource Optimization

- Review capacity utilization and future capacity requirements.
- Optimize machine loading, manpower and production layouts.
- Identify bottlenecks and drive debottlenecking initiatives.
- Support CAPEX requirements for capacity and productivity improvement.

7. Operational Excellence

- Standardize manufacturing systems, SOPs, KPIs and review mechanisms.
- Benchmark plants against each other and replicate best practices.
- Drive continuous improvement culture across the organization.
- Establish a solid data-driven operational review process.

8. Maintenance & Equipment Reliability

- Ensure high machine availability and reliability.
- Work with Maintenance teams to improve preventive/predictive maintenance.
- Reduce breakdowns and improve MTBF/MTTR.
- Ensure effective utilization and lifecycle management of critical equipment and moulds.

9. NPI & Production Readiness

- Ensure manufacturing readiness for new products and programs.
- Coordinate with Engineering, Tooling, Quality and R&D; for smooth industrialization.
- Ensure production achieves targeted quality, cycle time, capacity and cost from SOP onwards.





10. People & Leadership

- Lead Plant Heads and senior manufacturing teams.
- Build strong second-line leadership and succession plans.
- Develop a culture of accountability, discipline and continuous improvement.
- Drive skill development and manpower productivity.

Preferred candidate profile

- 15 to 20+ years of manufacturing experience, with significant experience in plastic manufacturing and high-precision components.
- Mandatory: Strong hands-on experience in precision plastic components, preferably precision injection moulding and related manufacturing processes.
- Experience managing multiple manufacturing plants and preferably multiple product/business divisions.
- Strong understanding of high-precision manufacturing, process capability, dimensional control, tooling/moulds and process optimization.
- Proven track record in improving OEE, productivity, yield, cycle time, rejection, scrap and manufacturing cost.
- Experience in Lean Manufacturing, TPM, Six Sigma, Kaizen and operational excellence.
- Strong exposure to capacity planning, production planning, manpower optimization and plant performance management.
- Experience working with automotive, medical, electrical/electronics, industrial or other precision-engineered plastic components would be preferred.
- Should have managed large manufacturing teams and worked closely with Quality, Engineering, Maintenance, Tooling, PPC and Supply Chain.
- Strong capability to standardize manufacturing practices across multiple plants and drive performance through Plant Heads.
- Should be a strong shop-floor-oriented operations leader, with the ability to manage both operational execution and continuous improvement.

📌 Head Manufacturing Operations (Chennai)
🏢 Amor Management Consultants
📍 Chennai