GM - Production - OTR Tyres

A specialised subsidiary for off highway tyres in domestic and international markets.

Role : GM - Production

Position Title : GM - Production

Department : Manufacturing

Level / Grade: GM

Reporting To Head - Plant Operations

Reportees Direct: 3 - 4

Key Purpose of the Job (Position Summary)

This position is responsible for achieving the defined production targets for the plant in terms of volume, quality and timelines with cost effectiveness by efficiently planning, coordinating, organizing and controlling the production process at the plant. The role will be responsible for enhancing the overall efficiency and productivity at the plant by undertaking improvement initiatives. The role will be responsible to maintaining the safety and health standards and the overall employee engagement levels in the Plant.

KEY PERFORMANCE AREAS

- Adherence to production plan / CLIP Achievement

- % Reduction in rejection and rework on account of quality

- % Reduction of scrap and wastage

- % Reduction in Conversion Cost

- % implementation of EHS policies and procedures at the plant

- % Compliance to all legal requirements related to EHS

- % Reduction in number of accidents at the plant

- % Reduction in consumption of indirect material

KEY ACTIVITIES & RESPONSIBILITIES

Planning & Budgeting

- Plan, implement and monitor the production schedule for the Plant based on the Sales plan and in coordination with the Plant Planning team (PPC)

- Forecasting and preparing the annual budgets for the function

- Coordinate, set up and implement standard operating procedure for all production operations

- Plan for manpower requirement (workmen and contract labour) in the plant and work with HR to ensure availability of workforce on production lines

- Work with the Industrial Engineering team to plan and ensure optimum utilization of all production resources and space, including stores space and inventory

- Plan for tools/ materials/ equipment's required for carrying out the production as per plan and provide the same to the Purchase team for procurement

- Plan for shutdown maintenance in consultation with the Engineering team

Production Operations

- Ensure achievement of production target as per production plan and standards with optimum utilization of resources and good coordination and teamwork across all the functions and areas

- Continuously monitor various production parameters like quantity and quality of material, machine utilization, uptime, etc. to proactively address likely issues

- Ensure other departments at the plant are updated well in time in case of any errors or deviations

- Coordinate with engineering departments for resolution of any technical problem such as breakdown of machinery/ equipment, leakage etc.

- Work with the Technology team to address issues and enhance/maintain the yield and make improvements in the process to get better efficiency

- Monitor inventory levels at the plant to ensure no disruption in the production process

- Ensure all material requisition is raised in a timely manner

- Identify and take necessary actions for continuous improvement in production process

- Ensure compliance to the defined processes and standards ensuring zero non conformity in internal and external audit

Production Quality

- Ensure reduction in in-process rejections and internal rework so as to attain efficient operations and cost reduction

- Continuously monitor resolution of frequent errors

- Liaison with the Quality team and Technology to address chronic issues

- Continuously work towards improving internal quality so as to reduce customer PPM and achieve high ratings on customer satisfaction index.

Efficiency & Productivity

- Ensure effective management of production lines to ensure maximum capacity utilization so as to attain the plant profitability target

- Plan for initiatives for continuous improvements to upgrade the quality and capacity of production process

- Identify and plan activities through 5S and 3M to improve work space for efficiency and productivity

- Work with the Industrial Engineering team to assess the MURI on the workers at the plant and identify ways to reduce the same

- Facilitate and support implementation of new systems and process improvements like OHSAS, ISO, SPARSH, QBM, Kaizen, etc.

Training

- Overall management of Associate training and deployment

- Drive the adoption of Self- Managed team philosophy with the managers and associates

Cost Reduction

- Work towards ensuring cost savings in variable costs through innovative ideas and optimum usage of raw materials, tools and consumables

- Work with the Engineering team to attain energy savings in the Production process

- Ensure efficient handling of the material and overall reduction in wastage

- Regularly liaison with the Stores and Purchase team for effective inventory planning

- Identify ways to reduce consumption of indirect material and implement the same at the plant

MIS and Reporting

- Monitor and review production expenditure to ensure compliance to the budget

- Ensure SAP is updated regularly and accurately by the team

- Ensure all production MIS is prepared and maintained by the respective Production Line Managers as per the defined formats and timelines

- Ensure preparation of any other report as and when required

Health and Safety

- Ensure safety measures are consistently and strictly followed on the production lines and take initiative to enhance acceptance of safety as a culture so as to achieve zero accident level

- Ensure all statutory, legal and procedural requirements on EHS are consistently complied with

- Ensure all employees are adequately trained with respect to EHS

- Conduct safety meetings of the department regularly to inculcate the importance of safety in the staff

- Report any incident to the VP - Plant Operations and EHS Head immediately

People and Relationship Management

- Manage performance of the team and ensure that team is working in line with organizational value system

- Ensure production staff is adequately trained and proactively work with HR at capability enhancement of team

- Conduct effective performance appraisals for the team and provide regular feedback

- Motivate, counsel and coach employees to ensure a conducive working environment

- Maintain good working relations with workmen and union members/operators to ensure a harmonious working environment at the plant

Education and Experience Required

Education:

Mechanical Engineer Experience:

16 - 20 years experience in a Production with at least 4-5 years of experience of leading production team for a plant

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