Job Purpose
- This position is being newly created to support the operations and expansion of the new manufacturing facility. The organization is seeking a strong leader to independently manage production and support the next phase of growth. The incoming incumbent will be responsible for driving operational KPIs, overseeing new product development, and supporting the transition towards full-scale operations.
- Given the dynamic nature of the facility, the role requires a hands-on leader with strong fabrication and manufacturing expertise and the ability to optimize operations based on evolving business requirements.
Technical Skills
Fabrication Engineering & Execution
- Lead fabrication of structural modules, skids, and heavy plate structures as per ASME and project standards.
- Manage fabrication involving plate thicknesses ranging from 20 mm to 150 mm.
- Drive fit-up, alignment, and dimensional control using laser alignment, total station, and advanced measurement techniques.
- Ensure correct joint design selection including butt, fillet, and groove welds based on load and service conditions.
Welding Engineering & Process Control
- Approve and standardize WPS, PQR, and WPQ.
- Demonstrate expertise in SMAW, GTAW (TIG), GMAW (MIG/MAG), SAW, FCAW, and orbital welding processes.
- Control heat input, interpass temperature, preheat/post-heat requirements, and distortion control techniques.
- Manage welding consumables, low hydrogen electrodes, flux handling, baking ovens, traceability, and batch control systems.
Material & Metallurgy Management
- Possess strong understanding of carbon steel, low alloy steel, stainless steel, duplex steel, and ASTM material grades such as A516, A106, A240 etc.
- Ensure PMI, MTC verification, and heat number traceability compliance.
- Oversee furnace and local PWHT operations including temperature cycle monitoring and documentation.
NDT & Quality Assurance
- Manage RT, UT, MT, PT, and VT inspection activities.
- Interpret radiography films and ultrasonic testing reports.
- Ensure compliance with ASME Section V, Section VIII, API standards (API 650/620), and related quality standards.
- Drive weld rejection reduction and root cause analysis of defects including slag, porosity, cracks, and lack of fusion.
Production Planning & Shop Floor Control
- Optimize cycle time, productivity, and shop load balancing across cutting, fit-up, welding, NDT, and painting operations.
- Drive plate nesting optimization, CNC plasma/laser cutting efficiency, material flow, and WIP control.
- Implement line balancing, bottleneck analysis, and welding arc-time improvement initiatives.
Codes, Standards & Compliance
- Ensure compliance with AWS D1.1 / D1.6, ISO 3834, and related fabrication and welding standards.
- Support ASME U Stamp / R Stamp readiness and welding quality system compliance.
- Manage third-party inspections, client audits, and quality documentation requirements (TPI – BV, TUV, DNV, Lloyd's).
Shop Automation & Modernization
- Drive implementation of robotic welding systems, CNC profile cutting machines, and automated fabrication lines.
- Possess exposure to ERP/MES integration, digital weld mapping, and fabrication traceability systems.
EHS – Fabrication Operations
- Ensure safety compliance for hot work, gas handling (O2, Acetylene, Argon), crane operations, rigging, and heavy lifting activities.
- Control welding fumes, ventilation systems, and fire prevention measures across fabrication bays.
Key Responsibilities
Project & Operations Management
- Lead large-scale projects ensuring execution within budget, timelines, and quality requirements.
- Oversee day-to-day production operations to ensure smooth manufacturing performance.
- Monitor KPIs, KRAs, productivity, and operational efficiency across manufacturing functions.
Procurement, Supply Chain & Resource Management
- Collaborate with procurement teams to ensure timely availability of raw materials and production resources.
- Oversee supply chain, logistics, inventory management, and finished goods distribution.
- Prepare and manage departmental budgets while controlling material, manpower, and operational costs.
Safety, Compliance & Risk Management
- Ensure compliance with safety, health, environmental, and regulatory requirements.
- Lead safety initiatives, sustainability programs, and environmental improvement measures.
- Develop crisis management and emergency response plans to ensure operational readiness and business continuity.
Technology, Innovation & Continuous Improvement
- Drive adoption of automation, AI, and advanced manufacturing technologies to improve operational efficiency.
- Identify opportunities for process improvement, modernization, and cost optimization.
- Lead continuous improvement initiatives focused on productivity, quality, and operational excellence.
Production Planning & Performance Monitoring
- Monitor production metrics, operational parameters, and delivery commitments to ensure target achievement.
- Drive corrective actions and performance improvement initiatives through operational reviews and data analysis.
- Manage manpower planning, workforce utilization, and capability development across teams.
New Product Development & Cross Functional Coordination
- Lead New Product Development (NPD) projects ensuring timely execution and customer satisfaction.
- Collaborate with engineering, sales, procurement, quality, and other cross-functional teams for seamless operations.
- Identify new tools, technologies, and business improvement opportunities to enhance manufacturing efficiency.
Stakeholder & Team Management
- Act as the primary operational interface for customers, suppliers, regulatory agencies, and internal stakeholders.
- Lead, mentor, and develop high-performing teams through structured performance management initiatives.
- Support hiring, succession planning, and employee development programs.
Financial & Business Performance
- Evaluate departmental profitability, operational risks, and overall business performance.
- Ensure manufacturing operations align with business objectives, profitability targets, and customer expectations.
Qualification & Experience
- Bachelor's Degree in Mechanical / Industrial / Production Engineering; MBA would be an added advantage.
- Certified Welding Engineer (CWE) / International Welding Engineer (IWE) certification preferred.
- 25+ Years of work experience
- Preferred backgrounds include Railways, Locomotive Manufacturing, Heavy Engineering, and Earth-Moving Equipment industries.
- Extensive experience in managing multi-plant fabrication operations with direct responsibility for heavy fabrication, welding engineering, production systems, and compliance with international manufacturing codes and standards.
- Demonstrates strong expertise in WPS/PQR qualification, welding metallurgy, distortion control, and code-based manufacturing practices (ASME/API/AWS), along with proven capability in executing large-scale, multi-project operations.
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