General Manager Operations

Job Title: Head of Operations – CNC Machining & Sub-Assembly (Aerospace & Défense)

Location: Peenya/ Devanhalli

Reports to: CEO

Team Size: 250 shopfloor + 30 engineers + 10 quality + supply chain

Experience: 20–25 years; min. 5 years as Ops Head in aerospace/defence machining & assemblies

Industry: Aerospace & Défense (Build-to-Print)

Employment Type: Full-time

Role Summary

Lead end-to-end operations for precision CNC machining (3/4/5-axis milling, turn mill) and mechanical sub-assembly aligned to aerospace & defence standards. Own OTD, cost, quality, safety, and compliance while scaling capacity, deploying Lean/Six Sigma , driving NPI , and ensuring traceability and configuration control . Partner with customers, quality, engineering, and supply chain to deliver right-first-time production at world-class levels.

Key Responsibilities

1) Operational Leadership

• Own daily operations across CNC machining , CMM inspection , assembly lines , in-process QC , maintenance , MRB , and logistics .
• Build and execute Master Production Schedule (MPS) ; ensure capacity planning , line balancing , and shift planning .
• Meet/exceed OTD, Quality (ppm/DPU), Cost, Safety targets; drive OEE , SMED , TPM , and 5S rigor.
• Govern process sheets , setup sheets , work instructions , Poka‑Yoke , own first-time yield and cycle time reduction.
• Run NPI, own FAI pack readiness & capability studies .

2) Quality & Compliance

• Ensure compliance to AS9100D , FAI , special process control ; manage NCR/CAR , RCCA/8D , PPAP-equivalents , SPC , PFMEA & Control Plans .
• Oversee traceability , part serialization , configuration management , document control , and calibration .

3) Assembly Operations

• Standardize kitting , BOM control , torque procedures , functional testing , and documentation .
• Enforce configuration control , revision discipline , and 100% traceability of assemblies.

7) EHS & Security

• Ensure EHS compliance , risk assessments , near-miss reporting , PPE , LOTO , hazardous waste handling .
• Adhere to relevant export controls /data security frameworks (e.g., SCOMET/ITAR/EAR-equivalent obligations via customer requirements).

8) People & Culture

• Build a high-performance culture: competency matrices, skill ladders, training (GD&T/ASME Y14.5, CAM, CMM), and shopfloor leadership .
• Coach managers; enable succession planning ; design recognition systems tied to KPIs.

9) Financials

• Own plant P&L levers: conversion cost , material variance , labour productivity , capital investment ROI, and throughput economics .

10) Customer & Stakeholder Management

• Lead customer audits , FAI reviews , contract performance meetings ; maintain VOC feedback loops.

Required Qualifications

• B.E./B. Tech in Mechanical.
• 20–25 years in precision machining and assemblies ; min. 5 years as Head of Operations in aerospace/defence .
• Strong command of AS9100D , AS9102 (FAI) , GD&T (ASME Y14.5) , SPC , PFMEA , RCCA/8D .
• Proven experience with 3/4/5‑axis CNC , complex fixtures , tight tolerances (≤10–20 µm) , metrology/CMM .
• Exposure to materials: Aluminium, Titanium, Inconel/Nickel alloys, Stainless , and associated cutting/tooling strategies.
• Familiarity with NADCAP processes (heat treatment, NDT, coatings) and managing qualified suppliers .
• Experience handling defence customer audits , security protocols, and confidentiality requirements .

Competencies

• Strategic Planning
• Advanced Manufacturing & Metrology
• Lean/Continuous Improvement & Problem Solving (A3/8D)
• Stakeholder & Customer Management
• Financial Acumen & Cost Control
• Leadership, Coaching, and Change Management
• Risk Management (technical, schedule, supply chain)
• Data Literacy (dashboards, analytics, variance analysis)

Behavioural Expectations

• Hands‑on, floor‑first leadership; visible Gemba presence
• High integrity for defence sector confidentiality
• Calm under schedule pressure; decisive & data‑driven
• Collaborative with Engineering, Quality, SCM; firm on standards