Production Manager

Job Code: 338/001/232
Industry: Steel Fabrication
Department: Production / Manufacturing
Reporting To: Operations Manager

Job Brief:
The Production Manager is responsible for planning, executing, monitoring, and continuously improving manufacturing operations for pressure vessels, skids, and fabricated products. The role ensures compliance with ASME standards, client specifications, delivery commitments, cost targets, and organizational goals. It emphasizes production efficiency, manpower optimization, safety, quality, and on-time delivery, while driving continuous improvement through data-driven decision-making and disciplined shop-floor management.

Job Responsibilities:
A. Production Planning & Execution

• Execute production activities according to approved project schedules, shop drawings, and Material Take-Offs (MTOs).
• Coordinate with Planning, Engineering, Quality, Procurement, and Projects departments to ensure uninterrupted production flow.
• Ensure daily, weekly, and monthly production targets are achieved without compromising safety or quality.
• Validate work sequences for pressure vessels and skids, including rolling, fit-up, welding, PWHT coordination, NDT, hydrotest, blasting, painting, and dispatch.

B. Production Efficiency & Man-Hour Control

• Implement and monitor the Production Efficiency Plan:
• Maintain man-hour reporting project-wise and group-wise.
• Track actual vs planned man-hours and initiate corrective actions for variances.
• Document and approve manpower transfers between groups.
• Drive productivity improvement initiatives to reduce rework, idle time, and bottlenecks.
• Control production overruns within acceptable limits; investigate and act on overruns beyond defined thresholds.

C. Manpower Management & Leadership

• Lead and manage supervisors, foremen, and production teams.
• Allocate manpower efficiently based on project priorities and skill requirements.
• Conduct regular toolbox talks, daily coordination meetings, and weekly performance reviews.
• Support training, mentoring, and skill development of welders, fitters, and supervisors.
• Promote a culture of ownership, discipline, accountability, and teamwork.

D. Quality & Compliance

• Ensure all production activities comply with approved drawings, WPS/PQR requirements, ITPs, Quality Plans, client specifications, statutory regulations, and ASME/ISO codes.
• Coordinate closely with QA/QC for inspections, NDT, hold points, and documentation readiness.
• Minimize rework through right-first-time execution and strict adherence to procedures.

E. Safety, Health & Environment (HSE)

• Ensure strict compliance with company HSE policies and site safety rules.
• Enforce safe work practices during lifting, welding, confined space work, hot work, and heavy fabrication.
• Participate in incident investigations and implement corrective/preventive actions.
• Support sustainability and environmental objectives.

F. Coordination & Communication

• Conduct daily production review meetings and weekly coordination meetings with Planning and Projects.
• Provide clear and timely production status updates to management.
• Highlight risks related to schedule, manpower, material availability, or equipment at an early stage.
• Support client visits, audits, and inspections.

G. Continuous Improvement & Digitalization

• Use historical production data to improve planning accuracy and execution efficiency.
• Support implementation of production dashboards, man-hour tracking systems, and performance KPIs.
• Identify opportunities for automation, process improvement, and layout optimization.
• Lead or participate in Lean / Kaizen initiatives.

Key Performance Indicators (KPIs):

• Delivery & Planning: On-time completion of production milestones, schedule adherence.
• Productivity & Cost: Planned vs actual man-hour variance, production efficiency improvement, rework percentage, overtime control.
• Quality: First-time-right acceptance rate, NCRs from production, and client inspection pass rate.
• Safety: LTIFR, safety violations/near misses reported and closed.
• People & Process: Manpower utilization rate, training hours per employee, supervisor, and workforce stability.