Production Management

• Execute daily production plan as per schedule.
• Ensure achievement of shift production targets.
• Monitor forging parameters such as temperature, tonnage, die alignment, and cycle time.
• Minimize rejection, rework, and downtime.
• Ensure optimum utilization of machines, dies, tools, and manpower.
• Coordinate with maintenance team for machine breakdowns and preventive maintenance.

Manpower Handling

• Allocate operators and helpers based on production requirements.
• Monitor discipline, attendance, and shift manpower utilization.
• Train and guide operators on safe working practices and process adherence.
• Conduct shift meetings and communicate production priorities.

Quality Control

• Ensure process compliance as per control plans and work instructions.
• Monitor forging defects such as laps, underfill, cracks, mismatch, and scale issues.
• Ensure first-piece approval and in-process inspections.
• Coordinate with QA team for corrective and preventive actions.

Safety & Compliance

• Ensure adherence to safety standards, PPE usage, and safe forging practices.
• Identify unsafe conditions and initiate corrective actions.
• Support implementation of 5S, Kaizen, TPM, and Lean activities.
• Ensure compliance with IATF, ISO, and company procedures.

Machine & Die Monitoring

• Monitor press/hammer performance and furnace conditions.
• Ensure proper die changing and die maintenance practices.
• Track die life and report abnormal failures.
• Ensure lubrication and cooling systems are functioning properly.

Documentation & Reporting

• Maintain shift production reports and rejection reports.
• Record downtime, breakdowns, and process abnormalities.
• Update production MIS and daily shift handover notes.
• Support audit documentation and traceability requirements.

Key Performance Indicators (KPIs)

• Production target achievement %
• Rejection and rework %
• OEE (Overall Equipment Effectiveness)
• Machine downtime
• Die life achievement
• Safety incidents
• Productivity per manpower
• On-time production completion
• 5S audit score

Required Qualifications

• Diploma / BE in Mechanical, Production, Metallurgy, or related field.
• 5–10 years of experience in forging operations.
• Experience in hot forging / closed die forging preferred.

Required Skills

• Knowledge of forging processes and metallurgy.
• Understanding of forging defects and corrective actions.
• Leadership and manpower management skills.
• Basic knowledge of TPM, Lean Manufacturing, and IATF requirements.
• Problem-solving and decision-making ability.
• Good communication and reporting skills.

Preferred Industry Experience

• Automotive forging
• Crankshaft / connecting rod / axle component forging
• Hot forging press or hammer operations