Manager - Production (TCD)

Creating Passion: Your Responsibilities

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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.