YourLiebherrCareer Manager Production (TCD)

Roles & Responsibilities:

A. Production Strategy Planning & Execution

• Own end-to-end production performance for tower crane fabrication welding machining coordination blasting painting sub-assembly and final assembly.
• Translate monthly/weekly production requirements into process-wise capacity manpower machine and shift plans in coordination with PPC/IE.
• Ensure production execution as per approved BOM drawings routing process flow standard times and production orders.
• Establish and monitor daily/weekly/monthly production targets and recovery plans for deviations.
• Identify and eliminate bottlenecks related to material manpower machine method tooling and capacity.
• Ensure controlled WIP flow between fabrication surface treatment and assembly processes.
• Ensure manufacturing readiness before production release including material drawings tooling fixtures equipment manpower and inspection readiness.

B. Fabrication & Welding Process Management

• Lead manufacturing of tower sections jib sections counter-jib slewing platforms machinery frames outriggers brackets and other structural assemblies.
• Ensure compliance with approved WPS/PQR welding parameters qualified welder requirements and applicable welding standards.
• Control critical welding parameters including preheat interpass temperature current voltage travel speed heat input and welding sequence.
• Ensure control of fit-up root gap alignment weld size distortion and dimensional stability.
• Ensure welding consumable identification storage baking issue and traceability.
• Monitor weld repair/NDT rejection and drive systematic reduction of welding defects.
• Establish effective distortion-control fixture-control and first-off approval practices.

C. Dimensional & Process Control

• Ensure manufacturing compliance with drawing requirements GD&T tolerances and defined CTQs.
• Establish controls for straightness flatness squareness parallelism hole diameter hole pitch positional accuracy and structural alignment.
• Ensure first-off in-process and final dimensional verification.
• Ensure availability capability and periodic verification of gauges fixtures templates and measuring equipment.
• Drive Poka-Yoke and error-proofing for critical/repetitive manufacturing operations.

D. Blasting & Painting Process

• Own production performance for surface preparation shot blasting primer intermediate coat top coat and curing.
• Ensure compliance with approved coating systems and process specifications.
• Control blasting parameters surface preparation surface profile and environmental conditions.
• Ensure control of paint mixing ratio pot life application parameters DFT inter-coat interval and curing.
• Drive improvement in paint consumption booth utilization throughput rejection and rework.

E. Assembly Process Management

• Ensure assembly is executed according to approved BOM drawings routing and Work Instructions.
• Control critical assembly parameters including fitment alignment clearances bolt torque lubrication pin/bushing fit and functional condition.
• Ensure operator self-inspection and Quality verification for identified critical characteristics.
• Ensure proper handling and protection of components throughout assembly.

F. Quality & Process Governance

• Own production-related quality performance while maintaining independent Quality verification/release.
• Ensure adherence to Process Flow PFMEA Control Plan Work Instructions Inspection Plans and Quality Gates.
• Monitor and improve FPY internal PPM rework scrap welding defects dimensional rejection and assembly defects.
• Lead structured RCA using 8D 5-Why Fishbone Pareto and other problem-solving methodologies.
• Ensure effective corrective/preventive action and standardization of improvements.
• Prevent unauthorized process deviations rework or component modifications.

G. Quality Gate NCR & Rework Management

• Ensure compliance with defined manufacturing Quality Gates from material release through final product release.
• Ensure NOK material is identified segregated and controlled.
• Ensure rework/repair is performed only against approved instructions and authorized disposition.
• Ensure reworked components undergo defined reinspection and release.
• Ensure NCR deviation concession and rework records are linked to relevant production orders/serial numbers.

H. Capacity Productivity & Cost Management

• Establish process capacity based on cycle time available hours efficiency manpower and equipment capability.
• Monitor OEE cycle time output/man-hour machine utilization and bottleneck capacity.
• Drive line balancing layout optimization material-flow improvement and manpower optimization.
• Reduce manufacturing losses related to waiting movement setup downtime rework scrap and excess consumption.
• Own production cost performance including labour welding consumables paint gas energy overtime and rework.
• Identify and justify CAPEX requirements for capacity quality and productivity improvement.

I. Manpower & Competency Development

• Define manpower requirements based on production volume process loading and shift pattern.
• Maintain and improve production skill matrix.
• Ensure qualified personnel for welding fabrication painting assembly and other critical operations.
• Develop multi-skilled workforce and succession capability.
• Identify skill gaps and establish technical training/qualification plans.
• Optimize permanent and contractual manpower deployment.

J. Equipment Tooling & Maintenance

• Ensure availability and capability of production-critical equipment cranes welding machines fixtures blasting and painting systems.
• Coordinate with Maintenance for preventive maintenance and equipment reliability.
• Monitor breakdown MTBF MTTR and equipment availability.
• Participate in URS technical evaluation FAT/SAT commissioning and process validation for new equipment.
• Ensure production tooling and fixtures remain capable and fit for use.

K. New Product / Process Industrialization

• Support NPD and product transfer activities through DFM/DFA process feasibility capacity assessment and manufacturing risk evaluation.
• Lead preparation/review of:
  • Process Flow
  • PFMEA
  • Control Plan
  • Work Instructions
  • Inspection Plans
  • Quality Gates.
• Coordinate pilot production first-off approval process validation and series-production release.
• Ensure lessons learned from existing products are incorporated into new processes.

L. Supplier & Cross-Functional Coordination

• Coordinate with PPC Quality IE SQM Purchase Engineering Maintenance Logistics Customer Quality and Finance.
• Support supplier development for production-critical components/processes.
• Escalate material supplier quality and capacity risks affecting production delivery.
• Drive cross-functional closure of chronic manufacturing issues.

M. Safety & Compliance

• Own production safety performance and ensure compliance with applicable EHS requirements.
• Ensure safe practices for heavy lifting welding gas cutting grinding blasting painting crane operation and material handling.
• Ensure PPE LOTO fire protection chemical handling and safe lifting requirements are implemented.
• Drive near-miss identification risk reduction and corrective actions.

N. Continuous Improvement & Digitalization

• Lead Lean Manufacturing VSM Kaizen 5S Poka-Yoke and standard-work initiatives.
• Drive reduction of manufacturing waste and process variability.
• Promote ERP/MES-based production reporting and traceability.
• Establish data-driven production dashboards and loss analysis.
• Standardize successful improvements across relevant production processes.

Qualification and Education Requirements:

Essential

• Bachelors Degree in Mechanical Engineering / Production Engineering / Manufacturing Engineering / Industrial Engineering.
• Strong technical understanding of heavy fabrication welding and mechanical assembly.

Preferred

• Masters / PG qualification in Manufacturing / Operations / Industrial Engineering.
• IWE / IWT / Welding Technology qualification highly desirable.
• Lean Six Sigma certification.
• Formal training in:
  • PFMEA
  • Control Plan
  • SPC
  • MSA
  • 8D / RCA
  • Manufacturing process improvement.
• Knowledge of ISO 9001 ISO 3834 and DIN EN 1090.

Experience:

• 1015 years of relevant manufacturing experience preferably in heavy engineering/heavy fabrication.
• Minimum 5 years in Production/Manufacturing Managerial responsibility.
• Strong hands-on experience in:
  • Structural fabrication
  • Welding
  • Dimensional control
  • Machining interface
  • Blasting & painting
  • Mechanical assembly.
• Experience managing multi-shift production operations.
• Proven experience in capacity planning manpower planning production scheduling and productivity improvement.
• Demonstrated track record of improving SQDCP performance.
• Experience with production KPIs OEE cycle-time improvement and cost reduction.
• Experience in new product/process industrialization is preferred.

Experience in tower cranes construction equipment heavy machinery material handling wind-energy equipment or similar heavy-engineering products is highly preferred

Have we awoken your interest Then we look forward to receiving your online application. If you have any questions please contact Saurabh Padmakar Kulkarni.

One Passion. Many Opportunities.