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

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 - )

Company – Tube Products of India, Avadi (Website Link - )

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

II. Cost Management and Profitability

III. SHE, TQM, and Employee Development

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

Skills

Functional Competencies