PRIME FUNCTION

To lead and manage the Tool Room and Forging Die function for Press and Hammer Shops, ensuring timely die development, manufacturing, repair and maintenance; enhancing die life; optimizing tooling costs; and ensuring uninterrupted production through reliable tooling availability. Ensure compliance with IATF 16949, ISO 14001, ISO 45001 and applicable safety requirements while developing technical capabilities and a strong safety culture within the Tool Room team.

JOB DESCRIPTION / RESPONSIBILITIES

Die Development and Manufacturing

• Lead Tool Room and forging die operations for Press and Hammer Shops.

• Manage die development, design, manufacturing, repair, trials and maintenance.

• Oversee VMC, Wire Cutting, trimming and piercing tool operations.

• Implement insert-type dies to reduce tooling costs and changeover time.

B. Die Life Enhancement and Failure Analysis

• Improve die life through material selection, heat treatment and surface treatment.

• Conduct failure analysis and implement corrective and preventive actions.

• Manage die welding repairs and establish die-life targets.

• Optimize die consumption and tooling cost per component.

C. Tooling Quality and Availability

• Ensure timely tooling availability and prevent production stoppages.

• Maintain die-life, repair, inspection and traceability records.

• Ensure dimensional accuracy, POP impression checks and DPT inspections.

• Monitor tooling costs, repairs and productivity.

D. Vendor Coordination and Development

• Manage vendors for die manufacturing, machining, heat treatment and repairs.

• Develop vendor capabilities, negotiate costs and monitor quality and delivery.

• Resolve vendor issues and ensure specification compliance.

E. Cross-Functional Coordination

• Coordinate with Production, Quality, Maintenance, PPC and Engineering.

• Support DWM, NPD, die trials, capacity planning and process improvement.

• Reduce downtime, die consumption, rejection and rework.

F. Quality System Compliance

• Ensure compliance with IATF 16949:2016 and customer requirements.

• Maintain PFMEA, Control Plans, SOPs and Work Instructions.

• Support audits, CAPA closure and tooling material traceability.

G. EOHS and Safety

• Ensure ISO 14001, ISO 45001, HIRA, PPE, machine guarding and LOTO compliance.

• Drive 5S, safety audits, waste management and risk reduction.

• Promote a zero-accident workplace.

H. Team Leadership and Development

• Lead Tool Room personnel and manage manpower and resources.

• Ensure adherence to quality, safety, 5S and standard procedures.

• Develop employee skills, second-line leadership and continuous improvement.

• Drive team productivity, cost reduction and problem-solving.

AUTHORITY

• Allocate Tool Room manpower, machines and resources in line with production priorities and approved plans.
• Prioritize die development, repair and maintenance activities based on production requirements.
• Recommend tooling design changes, die repair methods and process improvements within approved technical and quality standards.
• Recommend vendor selection, development and performance-related actions in accordance with the organization's procurement procedures.
• Initiate corrective and preventive actions for tooling-related quality, delivery, cost and safety issues.
• Recommend training, skill development and performance improvement actions for team members.
• Escalate critical tooling failures, production risks, safety concerns and resource constraints to the reporting manager.
• Exercise authority within the approved delegation of authority, budget and organizational policies.

JOB SPECIFICATION / COMPETENCY

Functional Competencies

• Forging Die Development and Maintenance

• Tool Room and Machining Operations

• Die Life Enhancement and Failure Analysis

• Heat Treatment and Welding

• Tooling Cost and Productivity Optimization

• Quality Systems and IATF Compliance

• Vendor Development and Management

• EOHS and Safety Management

Behavioural & Leadership Competencies

• Team Leadership and Development

• Analytical Thinking and Problem-Solving

• Decision-Making and Accountability

• Communication and Cross-Functional Coordination

• Planning and Execution

• Cost Consciousness

• Continuous Improvement

• Safety and Discipline

PERFORMANCE MEASURES

• Timely completion of die development, manufacturing, repair and modification against agreed schedules.
• Reduction in production line stoppages attributable to tooling and die-related issues.
• Improvement in die life against defined targets for critical dies.
• Reduction in die consumption and tooling cost per component.
• Improvement in die repair turnaround time and tooling availability.
• Reduction in die failures, repeat repairs and tooling-related quality defects.
• Achievement of Tool Room productivity, machining utilization and efficiency targets.
• Improvement in vendor on-time delivery, quality and cost performance.
• Timely closure of tooling-related customer complaints, audit findings and CAPA.
• Compliance with IATF 16949, ISO 14001, ISO 45001 and internal procedures.
• Achievement of 5S, safety audit and EOHS objectives, with a focus on zero accidents.
• Completion of employee skill development and cross-training plans.
• Implementation of measurable cost-saving and continuous improvement initiatives.

Skills

Competencies