Creating Passion: Your Responsibilities

Roles & Responsibilities:

A. Production Strategy, Planning & Execution

- Own end-to-end production performance for tower crane fabrication, welding, machining coordination, blasting, painting, sub-assembly and final assembly.
- Translate monthly/weekly production requirements into process-wise capacity, manpower, machine and shift plans in coordination with PPC/IE.
- Ensure production execution as per approved BOM, drawings, routing, process flow, standard times and production orders.
- Establish and monitor daily/weekly/monthly production targets and recovery plans for deviations.
- Identify and eliminate bottlenecks related to material, manpower, machine, method, tooling and capacity.
- Ensure controlled WIP flow between fabrication, surface treatment and assembly processes.
- Ensure manufacturing readiness before production release, including material, drawings, tooling, fixtures, equipment, manpower and inspection readiness.

B. Fabrication & Welding Process Management

- Lead manufacturing of tower sections, jib sections, counter-jib, slewing platforms, machinery frames, outriggers, brackets and other structural assemblies.
- Ensure compliance with approved WPS/PQR, welding parameters, qualified welder requirements and applicable welding standards.
- Control critical welding parameters including preheat, interpass temperature, current, voltage, travel speed, heat input and welding sequence.
- Ensure control of fit-up, root gap, alignment, weld size, distortion and dimensional stability.
- Ensure welding consumable identification, storage, baking, issue and traceability.
- Monitor weld repair/NDT rejection and drive systematic reduction of welding defects.
- Establish effective distortion-control, fixture-control and first-off approval practices.

C. Dimensional & Process Control

- Ensure manufacturing compliance with drawing requirements, GD&T;, tolerances and defined CTQs.
- Establish controls for straightness, flatness, squareness, parallelism, hole diameter, hole pitch, positional accuracy and structural alignment.
- Ensure first-off, in-process and final dimensional verification.
- Ensure availability, capability and periodic verification of gauges, fixtures, templates and measuring equipment.
- Drive Poka-Yoke and error-proofing for critical/repetitive manufacturing operations.

D. Blasting & Painting Process

- Own production performance for surface preparation, shot blasting, primer, intermediate coat, top coat and curing.
- Ensure compliance with approved coating systems and process specifications.
- Control blasting parameters, surface preparation, surface profile and environmental conditions.
- Ensure control of paint mixing ratio, pot life, application parameters, DFT, inter-coat interval and curing.
- Drive improvement in paint consumption, booth utilization, throughput, rejection and rework.

E. Assembly Process Management

- Ensure assembly is executed according to approved BOM, drawings, routing and Work Instructions.
- Control critical assembly parameters including fitment, alignment, clearances, bolt torque, lubrication, pin/bushing fit and functional condition.
- Ensure operator self-inspection and Quality verification for identified critical characteristics.




- Ensure proper handling and protection of components throughout assembly.

F. Quality & Process Governance

- Own production-related quality performance while maintaining independent Quality verification/release.
- Ensure adherence to Process Flow, PFMEA, Control Plan, Work Instructions, Inspection Plans and Quality Gates.
- Monitor and improve FPY, internal PPM, rework, scrap, welding defects, dimensional rejection and assembly defects.
- Lead structured RCA using 8D, 5-Why, Fishbone, Pareto and other problem-solving methodologies.
- Ensure effective corrective/preventive action and standardization of improvements.
- Prevent unauthorized process deviations, rework or component modifications.

G. Quality Gate, NCR & Rework Management

- Ensure compliance with defined manufacturing Quality Gates from material release through final product release.
- Ensure NOK material is identified, segregated and controlled.
- Ensure rework/repair is performed only against approved instructions and authorized disposition.
- Ensure reworked components undergo defined reinspection and release.
- Ensure NCR, deviation, concession and rework records are linked to relevant production orders/serial numbers.

H. Capacity, Productivity & Cost Management

- Establish process capacity based on cycle time, available hours, efficiency, manpower and equipment capability.
- Monitor OEE, cycle time, output/man-hour, machine utilization and bottleneck capacity.
- Drive line balancing, layout optimization, material-flow improvement and manpower optimization.
- Reduce manufacturing losses related to waiting, movement, setup, downtime, rework, scrap and excess consumption.
- Own production cost performance including labour, welding consumables, paint, gas, energy, overtime and rework.
- Identify and justify CAPEX requirements for capacity, quality and productivity improvement.

I. Manpower & Competency Development

- Define manpower requirements based on production volume, process loading and shift pattern.
- Maintain and improve production skill matrix.
- Ensure qualified personnel for welding, fabrication, painting, assembly and other critical operations.
- Develop multi-skilled workforce and succession capability.
- Identify skill gaps and establish technical training/qualification plans.
- Optimize permanent and contractual manpower deployment.

J. Equipment, Tooling & Maintenance

- Ensure availability and capability of production-critical equipment, cranes, welding machines, fixtures, blasting and painting systems.
- Coordinate with Maintenance for preventive maintenance and equipment reliability.
- Monitor breakdown, MTBF, MTTR and equipment availability.
- Participate in URS, technical evaluation, FAT/SAT, commissioning and process validation for new equipment.
- Ensure production tooling and fixtures remain capable and fit for use.

K.



New Product / Process Industrialization

- Support NPD and product transfer activities through DFM/DFA, process feasibility, capacity assessment and manufacturing risk evaluation.
- Lead preparation/review of: Process Flow PFMEA Control Plan Work Instructions Inspection Plans Quality Gates.
- Coordinate pilot production, first-off approval, process validation and series-production release.
- Ensure lessons learned from existing products are incorporated into new processes.

L. Supplier & Cross-Functional Coordination

- Coordinate with PPC, Quality, IE, SQM, Purchase, Engineering, Maintenance, Logistics, Customer Quality and Finance.
- Support supplier development for production-critical components/processes.
- Escalate material, supplier, quality and capacity risks affecting production delivery.
- Drive cross-functional closure of chronic manufacturing issues.

M. Safety & Compliance

- Own production safety performance and ensure compliance with applicable EHS requirements.
- Ensure protected practices for heavy lifting, welding, gas cutting, grinding, blasting, painting, crane operation and material handling.
- Ensure PPE, LOTO, fire protection, chemical handling and safe lifting requirements are implemented.
- Drive near-miss identification, risk reduction and corrective actions.

N. Continuous Improvement & Digitalization

- Lead Lean Manufacturing, VSM, Kaizen, 5S, Poka-Yoke and standard-work initiatives.
- Drive reduction of manufacturing waste and process variability.
- Promote ERP/MES-based production reporting and traceability.
- Establish data-driven production dashboards and loss analysis.
- Standardize successful improvements across relevant production processes.

Contributing Your Strengths: Your Qualifications

Qualification and Education Requirements:

Essential

- Bachelor's Degree in Mechanical Engineering / Production Engineering / Manufacturing Engineering / Industrial Engineering.
- Strong technical understanding of heavy fabrication, welding and mechanical assembly.

Preferred

- Master's / PG qualification in Manufacturing / Operations / Industrial Engineering.
- IWE / IWT / Welding Technology qualification – highly desirable.
- Lean Six Sigma certification.
- Formal training in: PFMEA Control Plan SPC MSA 8D / RCA Manufacturing process improvement.
- Knowledge of ISO 9001, ISO 3834 and DIN EN 1090.

Experience:

- 10–15+ years of relevant manufacturing experience, preferably in heavy engineering/heavy fabrication.
- Minimum 5 years in Production/Manufacturing Managerial responsibility.
- Strong hands-on experience in: Structural fabrication Welding Dimensional control Machining interface Blasting & painting Mechanical assembly.
- Experience managing multi-shift production operations.
- Proven experience in capacity planning, manpower planning, production scheduling and productivity improvement.
- Demonstrated track record of improving SQDCP performance.
- Experience with production KPIs, OEE, cycle-time improvement and cost reduction.
- Experience in new product/process industrialization is preferred.

Experience in tower cranes, construction equipment, heavy machinery, material handling, wind-energy equipment or similar heavy-engineering products is highly preferred

📌 Manager - Production (TCD) (India)
🏢 Liebherr Group
📍 India