Operations Leader, Precision Machining & Subassembly

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 capacityplanning, 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