Roles & Responsibilities

1. Production Planning & Shop Floor Execution

- Plan and schedule daily, weekly, and monthly production across VMC (4-axis) and HTL to maximize spindle utilization and meet delivery deadlines.

- Setup & Changeover Optimization: Implement techniques to minimize setup times, fixture changeovers, and prove-out delays for new and repeat batches.

- Bottleneck Management: Monitor work-in-progress (WIP) flow between operations to eliminate idle machine time and balance shift workloads.

1. Technical Leadership (VMC & HTL Processes)

- Process Engineering & Cycle Time Reduction: Review CNC part programs (Fanuc, Mitsubishi controls), cutting parameters (feeds, speeds, depth of cut), and tool paths to optimize cycle times.

- Tooling & Workholding Strategy: Oversee selection and standardization of tools, inserts, solid carbide end mills, hydraulic/pneumatic chucks, collets, and custom fixtures.

1. Current Product Development (NPD) & Process Engineering

- Feasibility Analysis: Conduct reviews on new customer drawings and 3D models to identify tolerance stack-ups, thin-wall distortion risks, and optimal machining sequences across VMC and HTL cells.

- Process Planning & Routing: Define end-to-end machining routings, operation sequences (OP10, OP20, etc.), datum schemes, and cycle time estimates for accurate RFQ costing and capacity planning.

- Fixture & Custom Tooling Design: Conceptualize and oversee the design, fabrication, and prove-out of custom hydraulic/pneumatic fixtures, tombstones, soft jaws, and special-form cutting tools.

- Multi-Axis CAM Strategy: Develop, review, and optimize 2-axis turning, 3-axis and 4th-axis milling programs (Mastercam or Fusion 360).





- High-Speed Machining (HSM) & Cycle Time Reduction: Apply advanced toolpath strategies to maximize metal removal rates (MRR), extend tool life, and reduce spindle cycle times.

- Simulation, Verification & Collision Avoidance: Enforce full machine kinematic simulation and G-code verification (Vericut or integrated CAM simulation) to eliminate crashes, gouges, and air-cutting prior to shop floor release.

- Post-Processor & Controller Standardization: Manage and fine-tune post-processors for Fanuc and Mitsubishi controllers; standardize sub-programs, canned cycles, probing routines (Renishaw), and custom macro B variables.

- Setup Documentation: Ensure programmers generate comprehensive setup sheets detailing work coordinate systems (G54G59), tool lists, stick-out lengths, coolant pressure requirements, and datum alignment notes.

- APQP & PPAP Execution: Lead cross-functional APQP (Advanced Product Quality Planning) milestones, including Process Flow Diagrams (PFD), PFMEA, Control Plans, Gage R&R;, process capability studies, and PPAP / First Article Inspection (FAI) submissions.

- Prototype-to-Production Handover: Manage dedicated prove-out runs, debug CNC programs, finalize Standard Operating Procedures (SOPs) and setup sheets, and formally hand over stabilized processes to regular production shifts.





1. Quality Assurance & Continuous Improvement

- Zero-Defect Culture: Partner with the Quality team to enforce in-process inspection protocols, GD&T; compliance, and Statistical Process Control (SPC) on critical-to-quality (CTQ) dimensions.

- Root Cause Analysis (RCA): Lead CAPA (Corrective and Preventive Action) investigations for scrap, rework, tool breakage, or dimensional drift using 8D, 5-Why, and Fishbone methodologies.

- Lean Manufacturing: Drive 5S housekeeping, Kaizen events, and scrap/rework reduction initiatives across all shifts.

1. Maintenance & Asset Reliability

- Preventive & Predictive Maintenance: Coordinate with the maintenance team to schedule preventive maintenance (PM) for spindles, ball screws, turrets, ATCs (Automatic Tool Changers), and coolant filtration systems to prevent unplanned breakdowns.

- Coolant & Chip Management: Enforce proper coolant concentration, tramp oil skimming, and chip disposal practices to extend machine longevity and prevent thermal distortion.

1. Team Leadership, Cost Control & EHS

- Workforce Management: Supervise, mentor, and evaluate shift supervisors, CNC setters, programmers, and machine operators; design skill matrices and cross-training programs for VMC and HTL operations.

- Cost & Budget Accountability: Control consumable tooling spend, overtime hours, power consumption, and raw material yield to meet monthly cost-per-part targets.

- Safety & Compliance: Enforce strict adherence to PPE usage, machine guarding, lockout/tagout (LOTO) procedures, and statutory Environment, Health, and Safety (EHS) standards.

📌 Production Head (Coimbatore)
🏢 Aadhiumay Metal Casting and Machining
📍 Coimbatore