Head of Operations – CNC Machining & Sub-Assembly (Aerospace & Defense)
Location: Peenya / Devanahalli, Bengaluru
Reports to: CEO
Team Size: 290 (250 shopfloor, 30 engineering, 10 quality + supply chain)
Experience: 20–25 years (min. 5 years leading Ops in aerospace/defense machining & assemblies)
Employment Type: Full-time
Role Overview
We are seeking a seasoned operations leader to drive end-to-end manufacturing excellence across precision CNC machining and mechanical sub-assemblies for aerospace & defense programs.
This role will own On-Time Delivery (OTD), Quality, Cost, Safety, and Compliance, while scaling operations, strengthening process discipline, and delivering right-first-time production at global benchmarks.
You will partner closely with Engineering, Quality, and Supply Chain, while being the face of operations for customers, audits, and program execution.
Key Responsibilities
1. Operations Leadership
- Lead daily operations across CNC machining (3/4/5-axis), CMM inspection, assembly, maintenance, and logistics
- Own Master Production Schedule (MPS), capacity planning, and line balancing
- Drive KPIs: OTD, OEE, FPY, Cost, Safety
- Institutionalize Lean Manufacturing (SMED, TPM, 5S, Kaizen)
- Improve cycle time, setup reduction, and throughput
- Lead NPI programs, including FAI readiness and capability validation
2. Quality & Compliance
- Ensure compliance with AS9100D and AS9102 (FAI)
- Drive SPC, PFMEA, Control Plans, RCCA (8D)
- Own NCR/CAR closure discipline
- Ensure full traceability, serialization, and configuration control
- Oversee calibration systems and document control
3. Assembly Operations
- Standardize kitting, BOM control, torque processes, and testing protocols
- Ensure revision discipline and 100% traceability in assemblies
- Drive error-proofing (Poka-Yoke) and right-first time builds
4. EHS & Regulatory Compliance
- Ensure adherence to EHS standards, LOTO, PPE, and risk assessments
- Drive safety culture through near-miss tracking and corrective actions
- Ensure compliance with export control frameworks (SCOMET / ITAR / EAR as applicable)
5. People & Culture
- Build a high-performance shopfloor culture
- Implement competency frameworks and skill matrices
- Drive training in GD&T (ASME Y14.5), CAM, and metrology
- Coach leadership team and establish succession pipelines
6. Financial Ownership
- Manage plant-level cost drivers:
- Conversion cost
- Labor productivity
- Material variance
- Capex ROI
- Drive throughput and margin improvement
7. Customer & Stakeholder Management
- Lead customer audits, FAI reviews, and performance reviews
- Act as escalation point for delivery/quality issues
- Maintain Voice of Customer (VOC) feedback loops
Required Qualifications
- B.E. / B.Tech in Mechanical Engineering
- 20–25 years in precision machining & assemblies
- Minimum 5 years as Head of Operations in aerospace/defense manufacturing
- Strong expertise in:
- 3/4/5-axis CNC machining & complex fixturing
- Tight tolerance machining (≤10–20 microns)
- CMM & metrology systems
- Deep knowledge of:
- AS9100D, AS9102, GD&T (ASME Y14.5)
- SPC, PFMEA, RCCA (8D)
- Experience with materials:
- Aluminum, Titanium, Inconel/Nickel alloys, Stainless Steel
- Familiarity with NADCAP processes and supplier management
- Proven track record handling defense/aerospace audits and compliance
Core Competencies
- Operational Strategy & Execution
- Advanced Manufacturing & Metrology
- Lean Transformation & Continuous Improvement
- Customer & Stakeholder Management
- Financial Acumen
- Leadership & Change Management
- Risk Management
- Data-Driven Decision Making
Behavioral Expectations
- Strong Gemba-driven leadership (shopfloor-first mindset)
- High integrity and discipline (critical for defense sector)
- Calm and decisive under pressure
- Collaborative, yet uncompromising on standards
What Success Looks Like (First 12 Months)
- OTD > 95% with stable MPS execution
- Measurable improvement in OEE (+10–15%)
- Reduction in internal rejection & rework
- Strong audit outcomes (customer + certification)
- Structured NPI pipeline with zero delayed FAI submissions
- Visible culture shift toward Lean & accountability
Growth Trajectory
- This role is positioned as a strategic leadership pipeline to Chief Operating Officer (COO) within a defined 3–4 year horizon, based on performance and business scale.
- Opportunity to transition from plant-level leadership to multi-site / multi-program ownership as the organization expands.
- Direct exposure to CEO, board-level decisions, and strategic customer engagements
- Lead future greenfield / brownfield expansions, including new facilities, capability additions, and global program ramps
- Play a key role in shaping organizational structure, leadership bench strength, and long-term manufacturing strategy
Scale Vision
- Aggressive expansion roadmap to significantly increase machining and assembly capacity over the next 3–5 years
- Planned investments in:
- Advanced 5-axis machining centers and automation (pallet systems, robotics)
- Digital manufacturing systems (MES, real-time dashboards, traceability platforms)
- Enhanced metrology and testing capabilities
- Expansion of capabilities across:
- High-complexity aerospace components and sub-assemblies
- Increased share of export-driven aerospace & defense programs
- Target to evolve into a globally competitive, AS9100/NADCAP-aligned manufacturing partner
- Strong focus on building a Lean, data-driven, high-throughput operation with world-class benchmarks in OTD, quality, and cost
- Opportunity to lead capacity ramp from current scale to next-level industrial footprint, including workforce scaling and supplier ecosystem development
