Head Manufacturing, PC Hyderabad

Job Description - Head Manufacturing

Head Manufacturing will be responsible for end-to-end production operations at the Hyderabad Production Company, covering the Machine Shop, Heat Treatment, and Maintenance functions. The role acts as a key enabler in aligning cross-functional teams, including Production Engineering, R&D, Purchase, and Product Marketing to deliver on operational excellence, product quality, and customer satisfaction.

The core focus of this role is to lead the implementation of Lean Manufacturing systems across the factory, embedding a culture of continuous improvement, waste elimination, and process standardization. The incumbent is expected to drive systemic efficiency improvements while ensuring strict adherence to process compliance, safety, and quality protocols.

This position carries the strategic responsibility of establishing a world-class manufacturing setup, promoting an accident-free, environmentally responsible, and highly collaborative work environment, and developing a capable team aligned to business performance goals.

Job Responsibilities:

Production Operations:

• Ensure plants meet production volume as per contract while achieving KPIs related to waste reduction and defect rates.
• Drive short lead times, high product availability (>95%), and minimal inventory through Lean manufacturing principles.
• Monitor and control daily operational consumables and reduce variances.
• Collaborate with maintenance to drive automation and enhance productivity and quality.
• Enforce adherence to Industrial Engineering standards and promote Statistical Process Controls.
• Build technical and functional capabilities within the production team.
• Lead continuous improvement initiatives to enhance productivity through new technologies and processes.
• Support localization and process improvements to reduce PK.
• Ensure seamless coordination with R&D (design), Quality, Purchase, and Logistics for efficient material flow.
  
  

Heat Treatment:

• Lead the Heat Treatment and Metallurgy team, ensuring process adherence and ISO/API compliance (9001:2015, 14001:2015, 45001:2018).
• Establish a robust quality assurance system for heat treatment processes.
• Optimize resource utilization through balanced in-house manufacturing and subcontracting.
• Maximize equipment availability (>95%) and uptime for heat treatment operations.
• Promote continual improvement in metallurgical practices and support steel supplier development.
• Contribute to R&D in material science and expedite development of new parts (NPD).
• Champion Lean and continuous improvement projects within the heat treatment function.
• Enforce compliance with the Business Code of Practice and drive PK reduction through innovation.
  
  

Maintenance:

• Partner with production to deliver targeted volumes by ensuring optimal plant uptime and OEE performance.
• Support process improvement via technology upgrades and technical guidance during equipment installation and commissioning.
• Build maintenance team capability using FMECA, RCA, and reliability improvement tools.
• Lead new project implementations with attention to cost, schedule, and EHS standards.
  
  

Lean Implementation & Continuous Improvement:

• Champion Lean manufacturing principles across production, maintenance, and heat treatment areas to eliminate waste, improve flow, and enhance efficiency.
• Lead the deployment of Lean tools such as 5S, Kaizen, Value Stream Mapping, SMED, Visual Management, and Kanban.
• Conduct regular Lean workshops and Gemba walks to identify improvement areas and promote a culture of continuous improvement.
• Monitor and report Lean KPIs (OEE, First Pass Yield, Inventory Turns, etc.) and ensure alignment with plant performance goals.
• Build Lean capabilities within teams by coaching and mentoring employees at all levels.
• Integrate Lean thinking into daily operations, decision-making processes, and long-term strategic planning.
• Ensure sustainability of Lean initiatives by institutionalizing standard work, visual controls, and performance review mechanisms.
  
  

Educational: B.E. / B. Tech / M. Tech – Mechanical / Metallurgy Engineering

Experience Requirement:

• Minimum 15 years of experience in a manufacturing/production environment, preferably within Auto, Mining, Engineering, or Heavy Industrial sectors.
  
  

Knowledge:

• Demonstrated experience in leading Production, Heat Treatment, and Maintenance functions with exposure to Metallurgy, Quality Systems, and EHS practices.
• Proven track record in implementing Lean Manufacturing systems (e.g., 5S, Kaizen, SMED, TPM, Visual Management) and driving Lean cultural transformation at plant level.
• Hands-on experience in driving productivity improvements, cost reduction initiatives, and team capability building through structured Lean interventions.
• Experience in leading cross-functional teams and aligning manufacturing strategies with business objectives.
  
  

Skills & Behavioural Competencies:

Functional:

• Strong understanding of Lean manufacturing, process engineering, and equipment reliability
• Expertise in Heat Treatment, Metallurgical Quality, and Process Control
• Experience with productivity improvement tools (Kaizen, TPM, 5S, SPC)
  
  

Behavioural:

• Excellent communication and facilitation skills.
• Strong planning and prioritization abilities.
• Effective cross-functional collaboration.
• High adaptability and learning agility.
• Capable of multitasking and delivering in high-performance environments.
  
  

People & Leadership:

• Proven experience in manpower management and team development.
• Influencing and stakeholder management skills.
• Championing a culture of discipline and performance.
  
  

Safety & Environment:

• Strong commitment to health and safety standards.
• Familiar with hazard assessments, risk analysis, and safety audits.
• Experience in driving safe behavior and compliance across operations.
  
  

DECISION MAKING AUTHORITY: "Decisions" in this context will include deciding work priorities, deciding between alternative courses of action, deciding what to recommend.

• Driving shop floor discipline and operational excellence.
• Deployment and allocation of manpower across production functions.
• Cost strategy decisions related to waste reduction, conversion cost, and operating consumables
• Talent development including performance management (KPI-driven), closure of PDPs, and technical training for team members.
• Developing, implementing, and monitoring internal control systems and procedures.
• Adherence to company policies, safety norms, and compliance requirements.
• Strategic ownership and execution of Lean Manufacturing initiatives, including prioritization of improvement projects, resource allocation, and sustainability of Lean culture.
  
  

REPORTING STRUCTURE:

• Reporting to: General Manager, Hyderabad PC.
• Direct subordinate: Team Manager - Production (RDT), Team Manager - Production (RGU), Team Manager - Metallurgy & Operations, Manager Plant Maintenance.
  
  

Epiroc is a global productivity partner for mining and construction customers, and accelerates the transformation toward a sustainable society. With ground-breaking technology, Epiroc develops and provides innovative and safe equipment, such as drill rigs, rock excavation and construction equipment and tools for surface and underground applications. The company also offers world-class service and other aftermarket support as well as solutions for automation, digitalization and electrification. Epiroc is based in Stockholm, Sweden, had revenues of more than SEK 60 billion in 2023, and has around 18 200 passionate employees supporting and collaborating with customers in around 150 countries. Learn more at www.epiroc.com.