Assembly Manager For HCU ( New Assembly Station

Role To lead and manage the complete assembly operations of HIP Turbine systems, ensuring precision assembly, adherence to stringent quality standards, on-time delivery, and continuous improvement in safety, productivity, and cost efficiency. Key Responsibilities 1. HIP Turbine Assembly Management Lead end-to-end assembly of HIP turbine modules including: Casings Rotors and shafts Blade assemblies Internal components and sealing systems Ensure compliance with engineering drawings, specifications, and tolerances Manage stage-wise assembly from sub-assembly to final build 2. Precision & Critical Fitment Control Ensure high-precision operations including: Rotor alignment and balancing readiness Bearing clearances and axial/radial positioning Critical torqueing and fastening sequences Oversee dimensional checks, runouts, and concentricity measurements Coordinate with metrology/inspection teams for critical verification 3. Production Planning & Execution Execute assembly schedules aligned with PPC and project timelines Monitor progress vs. plan and take corrective actions to avoid delays Identify and resolve bottlenecks in assembly sequence Optimize line balancing and takt time for HIP assembly 4. Quality Assurance & Testing Ensure zero-defect assembly by implementing stage inspections Coordinate for: Hydraulic & pressure testing Leak checks Functional verification of assembled turbine units Lead root cause analysis (RCA) and implement CAPA for failures 5. Shopfloor Productivity & Cost Control Improve productivity (output per man-hour) Reduce rework, rejection, and cycle time losses Drive cost reduction through process improvements and waste elimination Monitor and control Cost of Poor Quality (COPQ) 6. Safety & Compliance (HSE) Ensure safe handling of heavy components, rotors, and high-pressure systems Conduct: Daily toolbox talks Risk assessments and safety audits Ensure proper usage of lifting tools, fixtures, and PPE Promote zero-LTI safety culture 7. Continuous Improvement & Lean Initiatives Implement Lean tools: 5S Kaizen Poka-Yoke Standard Work Drive cycle time reduction and process stability Develop and standardize best assembly practices 8. Cross-Functional Coordination Coordinate with: Design Engineering technical clarifications and deviations PPC schedules and priorities Supply Chain availability of critical components QA/QC inspections and clearances Support customer inspections and audits 9. Team Leadership & Skill Development Lead assembly supervisors, engineers, and technicians Develop skill matrix for HIP turbine assembly competencies Train workforce in precision assembly techniques and safety practices Drive accountability, discipline, and performance culture 10. Equipment, Tooling & Fixtures Management Ensure availability and upkeep of: Specialized HIP assembly fixtures Alignment tools and dial gauges Torque tools and hydraulic equipment Work with maintenance for preventive maintenance and uptime improvement 11. Documentation & MIS Reporting Maintain: Assembly records and check sheets Inspection and test reports Deviation and NCR records Track and present KPIs in daily/weekly reviews Key Performance Indicators (KPIs) On-Time Delivery (OTD) for HIP turbines Assembly Cycle Time Alignment / clearance deviation levels Rework and rejection rate Productivity (Man-hour efficiency) Safety (Zero LTI) COPQ reduction