Manufacturing Shop Operations Team Manager - Senior

Job Summary

The Senior Manager / Manager – Camshaft Manufacturing Operations is responsible for leading day-to-day manufacturing operations for camshafts across QSK, KV, NT, ISX, and other engine platforms at Kothrud Engine Plant. The role focuses on ensuring safe, efficient, and high-quality production through effective management of machining processes, manpower, equipment performance, automation systems, and continuous improvement initiatives.

The incumbent will lead operations involving cam milling, grinding, induction hardening, straightening, superfinishing, washing, inspection, and packaging processes while ensuring achievement of safety, quality, delivery, cost, and productivity targets. The role also requires strong coordination with cross-functional teams including Manufacturing Engineering, Quality, Maintenance, Planning, and Supply Chain.
 

Key Responsibilities

Production & Operations Management

• Execute and monitor daily production plans to meet customer delivery schedules and operational targets.
• Ensure smooth operation of manufacturing lines with focus on safety, quality, productivity, and cost optimization.
• Manage manpower deployment, shift planning, absenteeism control, and resource utilization.
• Coordinate with planning, quality, maintenance, and manufacturing engineering teams to minimize downtime and production losses.
• Drive production stability across multiple camshaft variants and engine platforms.
• Lead and manage daily operations of cylinder head machining lines. 
• Drive high-mix, high-volume production while maintaining flexibility and efficiency. 
• Optimize manpower utilization, line balancing, and throughput. 
• Collaborate with cross-functional teams including Supply Chain, Quality, Maintenance, and Engineering to ensure seamless operations. 
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Equipment & Process Management

• Oversee end-to-end machining processes including:
• Oversee operation and performance of critical manufacturing equipment including:
  • Cam Milling Machines
  • Journal & Cam Lobe Grinding Machines
  • Induction Hardening Systems
  • Straightening Machines
  • Superfinishing Machines
  • BHN Testing & Crack Detection Systems
  • Washing, Laser Marking & Final Inspection Machines
• Ensure adherence to preventive and predictive maintenance schedules for improved equipment reliability.
• Support machine trials, process validation, commissioning, and production ramp-up activities.
• Monitor process capability and implement corrective actions to sustain process stability.

Automation & Manufacturing Systems

• Support implementation and stabilization of automation systems such as robotic handling, gantry systems, and automated inspection systems.
• Drive CMS (Cummins Manufacturing System) implementation and sustainment across the shop floor.
• Participate in Industry 4.0 and digital manufacturing initiatives to improve operational visibility and machine utilization.
• Promote data-based decision-making through operational reviews and KPI tracking.

Quality, Safety & Compliance

• Ensure adherence to Cummins quality standards and customer requirements.
• Lead root cause analysis and implementation of corrective/preventive actions for process and quality issues.
• Drive reduction in scrap, rework, and customer complaints.
• Ensure compliance with HSE, environmental, ergonomic, and statutory requirements.
• Support audits, VPCR activities, layered process audits, and quality improvement initiatives.

Team Leadership & Development

• Lead and develop supervisors, operators, technicians, and support staff.
• Foster a culture of accountability, teamwork, discipline, and continuous improvement.
• Conduct training, skill development, performance reviews, and competency enhancement initiatives.
• Encourage employee involvement in Kaizen, safety, and productivity improvement activities.

Continuous Improvement & Cost Optimization

• Improve OEE, productivity, cycle time, and process efficiency.
• Drive Lean Manufacturing initiatives including 5S, TPM, Kaizen, SMED, and waste elimination.
• Support cost reduction initiatives related to tooling, consumables, utilities, and manpower optimization.
• Participate in CAPEX execution, operational budgeting, and resource planning activities.