Cluster Head - Sheet Metal

Cluster Head – Sheet Metal / FMCD Industry: Consumer Durable & Appliances Location: Bangalore Reporting To: Head Of Operations

1. Role Overview We are looking for a seasoned manufacturing leader to head a large-scale, multi-product manufacturing cluster involving fabrication, assembly, finishing, and packaging operations. The role requires end-to-end ownership of the manufacturing value chain, with a strong focus on press shop, sheet metal fabrication, high-volume assembly, surface finishing, and finished goods packaging. The incumbent will be responsible for driving excellence across safety, quality, cost, delivery, and productivity, while managing high SKU complexity and consumer-facing product standards.
2. Key Accountabilities 2.1 End-to-End Manufacturing Ownership Lead complete manufacturing lifecycle: Press Shop → Fabrication → Assembly → Finishing → Packaging → Dispatch Drive performance across SQCDP (Safety, Quality, Cost, Delivery, Productivity) metrics Ensure achievement of production targets aligned with business plans 2.2 Press Shop & Sheet Metal Operations Oversee press shop activities including: Blanking, punching, bending, forming, deep drawing Drive: Tooling efficiency and die maintenance Quick changeovers and downtime reduction Improve: Material utilization and yield Scrap and rejection levels Ensure dimensional accuracy critical for downstream processes 2.3 Fabrication & Structural Integration Lead fabrication processes involving sheet metal structures and assemblies Ensure: Precision in fitment Consistency in structural integrity Drive process standardization and repeatability 2.4 Assembly Operations (High Mix / High Volume) Manage multiple assembly lines with diverse product configurations Drive: Line balancing and takt time optimization Throughput and productivity improvements Handle complex SKU mix and frequent product changeovers 2.5 Finishing Operations Oversee surface finishing processes such as: Powder coating / painting Buffing and polishing Ensure: Uniform finish quality Corrosion resistance and durability Premium aesthetic standards for end customers 2.6 Packaging & Dispatch Excellence Design and implement robust packaging systems to prevent transit damage Optimize packaging cost and material efficiency Ensure readiness for large-scale dispatch operations Drive improvements in logistics coordination and delivery timelines 2.7 Quality Management Drive a zero-defect manufacturing culture Reduce: Rework and rejection Field failures and customer complaints Lead structured problem-solving: Root Cause Analysis (RCA) Corrective & Preventive Actions (CAPA) 2.8 Safety & Compliance Ensure adherence to all statutory, regulatory, and internal safety standards Drive a culture of zero harm and safe manufacturing practices Ensure readiness for internal and external audits 2.9 Cost Optimization & Productivity Drive continuous cost reduction through: Process improvements Waste elimination Material optimization Improve: Overall Equipment Effectiveness (OEE) Labor productivity 2.10 Supplier & Cross-Functional Collaboration Work closely with supply chain and vendors for: Raw materials and fabricated components Critical bought-out parts Ensure supplier quality, on-time delivery, and cost efficiency Collaborate with engineering, quality, and planning teams 2.11 New Product Introduction (NPI) Lead industrialization of new products from design to production Ensure readiness in: Tooling and fixtures Assembly lines Packaging solutions Drive smooth ramp-up with minimal defects 2.12 Team Leadership Lead large cross-functional teams across: Press shop Fabrication Assembly Finishing Packaging Build a high-performance culture focused on accountability and continuous improvement
3. Key Performance Indicators (KPIs) Safety performance (Zero incidents) OEE across manufacturing operations First Pass Yield (FPY) Scrap, rework, and rejection rates Cost per unit / productivity metrics On-time delivery (OTD) Customer complaints / field failure rates Requirements
4. Candidate Profile Education Diploma / BE in Mechanical / Production / Industrial Engineering Experience 15–20+ years in manufacturing leadership roles Strong background in consumer durables / appliances manufacturing preferred Mandatory Experience Press shop and sheet metal fabrication Assembly operations (multi-product) Finishing processes (painting/coating) Packaging and dispatch systems Preferred Experience Home & Kitchen appliance manufacturing Exposure to electrical appliances Experience in appliances manufacturing and safety compliance
5. Core Competencies End-to-end manufacturing expertise (raw material to finished goods) Strong command over press shop and fabrication processes Operational excellence in assembly and packaging systems Lean Manufacturing, Six Sigma, and cost optimization Leadership in high-volume, high-mix manufacturing environments
6. Role Impact This role is critical in ensuring delivery of high-quality, aesthetically superior, and safe appliances, with full ownership of manufacturing efficiency, cost competitiveness, and customer satisfaction. The Cluster Head directly influences plant performance, product quality, and brand reputation in the market.