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Associate General Manager - Engineering (Electric Resistance Welded Tube Production)

Associate General Manager - Engineering (Electric Resistance Welded Tube Production)

Tube Products Of India Limited.Chennai, Tamil Nadu, India
6 days ago
Job description

Job Description : AGM – ERW Production(Precision Steel Tube Mill Plant)

Job Title : AGM – ERW Production (Electric Resistance Welded Tubes)

Group : Murugappa / Engineering (TI India) – (Website Link - https : / / www.murugappa.com / )

Company – Tube Products of India, Avadi (Website Link - https : / / tiindia.com / tube-products-of-india / )

Industry : Engineering

Location : Avadi (Chennai, Tamil Nādu)

Reporting to : Plant Head

Experience : 12 to 18 Years

Qualification : Engineering

Purpose of the Role

The primary purpose is to achieve budgeted production volumes of high-quality products and the set target of On-Time In-Full (OTIF). This is accomplished by establishing robust processes and systems in Operations with a focus on Safety, Health, and Environment (SHE), Quality, Productivity, Cost Control, Operational Efficiency, and Employee Welfare, ensuring alignment with the Business requirements and Business Plan.

Critical Aspects & Requirements (Specialized Experience)

The role requires specific, profound experience in the precision steel tube making industry :

  • Experience in Precision Steel Tube Making : A minimum of 15 to 20 years of knowledge and practice.
  • Troubleshooting Skills : Expertise in troubleshooting Precision Steel Tube Mill Operations, specifically concerning :
  • Knowledge and practice of HF Induction Welding Fundamental Principles.
  • Roll Tooling Function & Tooling Maintenance for Precision Steel Tube Mills.
  • ID Scarfing Tooling arrangements for Precision Steel Tube Mills.
  • Autonomous Maintenance & Planned Maintenance Programs for Tube Mills.
  • Tube Mill Alignment & Inspection Techniques.
  • Precision Tube Mill Set-up techniques & Setting qualification Procedures, including Weld Forge line Micro.
  • Product Expertise : Knowledge and practice of Precision Steel Tube Product Specification & Special requirements for different categories of applications.
  • Process Qualification : Knowledge and practice of Tube Mill Process qualification & NDT flaw detection techniques and methods.
  • New Product Development (NPD) : Exposure to NPD with assessment of Tube Mill considerations.
  • Advanced Steel Grades : Knowledge & practice of manufacturing techniques for Precision Steel Tubes using High-Strength Low-Alloy (HSLA) & Advanced High-Strength Steel (AHSS) grades.
  • Abnormality Identification : Skills for identification of abnormalities in Equipment / Tooling (Rolls).
  • Analytical Ability : The capability to relate operational parameters for enhanced process control and the stratification of data for a better understanding of process results.

Role & Responsibilities / Key Accountabilities

I. Production, Quality, and Operational Excellence

  • Volume & Delivery : Achieve budgeted volumes of Production and 85% OTIF (On-Time In-Full) to the customers. Accountable for Production Volume and On-Time Delivery (OTD).
  • Quality Management : Achieve High Quality Products (100% FTR).
  • Develop and monitor the adherence of Quality Standards and Parameters.
  • Eliminate the top three defects : weld crack, surface defects, and dimensional defects at in-house, aiming for Zero Customer Complaints / Zero PPM at the Customer's end.
  • Accountable for In Plant Rejections and Customer Rejections & Complaints.
  • Drive a TQM culture.
  • Efficiency & Resources : Utilize existing resources effectively , focusing on planning, machine effectiveness, and man productivity.
  • Improve Overall Equipment Efficiency (OEE).
  • Manage resources (Machines & Material) effectively.
  • Ensure effective utilization of Tube Mills and control Work-In-Progress (WIP) through coordination with Planning.

    • II. Cost Management and Profitability

  • Cost Control : Reduce fixed costs (man-power) and variable costs (fuel and yield) through short-term and long-term projects.
  • Control expenditure by monitoring and executing planned actions to achieve budgeted manufacturing cost and improve profitability.
  • Accountable for Material Yield and Productivity , Specific Energy Consumption (ensuring within budgeted level) , and Consumable & Tool cost control.
  • Generate and implement CAPEX & SREP Proposals.

    • III. SHE, TQM, and Employee Development

  • Safety & Compliance (SHE) : Achieve 100% SHE Performance.
  • Ensure compliance with all statutory requirements and 100% adherence to ISO / TS, SHE & ERP.
  • Generate & Implement Improvements for Safety & Ergonomics of Operators.
  • Accountable for Safety.
  • TQM and Operational Excellence : Take a key role in the implementation of TQM and driving Total Employee Involvement (TEI).
  • Drive TQM culture and utilize TQM / TPM Tools and Techniques.
  • Generate & Implement Operational Excellence, Lean & TPM Improvements and Kaizens.
  • Monitor and review progress of Kaizen, SGAs, and CFTs.
  • Accountable for Operational Excellence, Lean & Total Productive Maintenance (TPM) initiatives.
  • Maintenance : Accountable for Maintenance of equipment.
  • Coordinate with Maintenance for periodical Preventive Maintenance, up-keeping of Equipment condition & Spares procurement and Maintenance.
  • Coordinate with Tool Room for Roll Maintenance, Abnormality correction and improvements.
  • People Management & Development : Assess and enhance the capabilities of the Workforce (Associates) through functional expertise training (classroom and floor).
  • Training topics include safety in materials handling, product application, autonomous maintenance, tooling maintenance, and skill rotation.
  • Develop subordinates for improving their capabilities & Knowledge.
  • Ensure effective management of Manpower.
  • Maintain discipline and morale among employees at the shop floor.
  • Handle employee grievances and provide counselling to Managers, Engineers, and Employees.
  • Inter-functional Coordination : Connect leaders from SHE, Planning, Materials, Quality, Maintenance, Sales & Marketing, TQM, NPD and HR in different forums to drive initiatives for manufacturing process excellence.

    • Specific Accountabilities

    This position is accountable to the Plant Head and for the Tube Mills and ERW Finishing operations in the following specific areas :

    Production Volume

    Achievement of Planned volume on a Month wise / Annual basis.

    Material & Cost

    Achievement of budgeted yield on a Month wise / Annual basis.

    Ensuring Energy consumption is within the budgeted level.

    Consumable & Tool cost control.

    Operational Efficiency

    Improvement of Overall Equipment Efficiency (OEE).

    Delivery

    Ensuring On-Time Delivery (OTD) for ERW major customers.

    Quality

    Reduction of In-plant Rejections - ERW.

    Reduction of Customer Rejection & Complaints.

    New Product

    Rolling of New Product Development (NPD) sizes as per Plan.

    Continuous Improvement

    Generation & Implementation of Operational Excellence, Lean & Total Productive Maintenance (TPM) Improvements and Kaizens.

    Generation & Implementation of Improvements for Safety & Ergonomics of Operators.

    Maintenance & Projects

    Co-ordination with Maintenance for periodical Preventive Maintenance, up keeping of Equipment condition & Spares procurement and Maintenance.

    Identification, Generation & Implementation of CAPEX & SREP Proposals.

    Co-ordination with Tool Room for Roll Maintenance, Abnormality correction and improvements.

    Planning & Inventory

    Co-ordination with Planning for effective utilization of Tube Mills, and for Controlling Work-In-Progress (WIP).

    People Management

    Ensuring discipline and morale among Employees at Shop Floor.

    Developing Sub-ordinates for improving their capabilities & Knowledge.

    Required Knowledge, Skills, and Functional Competencies

    Knowledge

  • OHSAS & ISO14001
  • Quality Management Systems
  • Maintenance System
  • Business Plan
  • Manufacturing Technology
  • Product Application
  • Inventory Control
  • TQM / TPM Tools and Techniques
  • Budgeting Process
  • Recovery & Contingency Planning
  • Operational Excellence and Lean practices

    • Skills

  • Attention to details
  • Critical Thinking (Troubleshooting)
  • Problem Solving
  • Decision Making
  • Cost Conscious
  • People Development
  • Innovation
  • Customer Centricity
  • Escalation and Reporting
  • Analytical ability to stratify data
  • Ability to maintain discipline

    • Functional Competencies

  • Production Management
  • Quality Management
  • Cost Management
  • Inventory Management
  • SHE & Compliance Management
  • Training & Development
  • TQM Promotion & Management
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