DGM-Plant Operations

We are seeking a hands-on, technically strong DGM – Plant Operations to lead end-to-end manufacturing of EV AC and DC chargers for the automotive sector (cars, buses, and off-road/industrial vehicles). This is a design-and-manufacture environment spanning PCB assembly (PCBA/SMT), sheet-metal fabrication of cabinets, IM (injection-moulded) part enclosures, electro-mechanical assembly of components such as MCCBs, energy meters, MCM (metering/control modules), PLCs and other hardware, through to End-of-Line (EOL) functional testing and dispatch. The role owns the entire plant floor — production, quality, fabrication, PCBA, assembly, testing, and people — and is accountable for on-time, first-time-right delivery of chargers that meet automotive/EV safety and performance standards.
Key Responsibilities
1. Overall Plant & Manufacturing Operations
Own end-to-end plant operations for EV AC & DC charger manufacturing — from raw material/component receipt through PCBA, fabrication, sub-assembly, final assembly, EOL testing, packing and dispatch.
Develop production plans, capacity plans, and manpower plans aligned to sales/order forecasts across charger models and power ratings.
Drive daily production reviews, shift planning, and resource allocation to meet delivery commitments (OTIF) for OEM and aftermarket customers.
Establish and track plant KPIs — OEE, throughput, first pass yield (FPY), rejection/rework %, on-time delivery, manpower productivity, and cost per unit.
Drive Lean Manufacturing, 5S, Kaizen, Six Sigma and TPM practices across all shop floors (SMT, assembly, testing).
2. PCBA / SMT Line Management
Manage the PCBA/SMT line end-to-end — SMT placement, reflow soldering, THT/wave soldering, AOI, ICT, and functional/board-level testing of power and control PCBs used in chargers.
Ensure SMT line yield, changeover time, first-pass-yield, and defect-rate targets are met; drive root-cause analysis (RCA) and CAPA for PCBA defects.
Coordinate NPI (New Product Introduction) for new charger boards — DFM/DFA reviews with R&D/design teams, prototype builds, pilot runs, and ramp-up to volume production.
Oversee SMT stencil, feeder, reel management, ESD control, and calibration of SMT/soldering equipment.
3. Fabrication, Enclosure & Cabinet Manufacturing
Oversee sheet-metal fabrication of steel cabinets/enclosures — cutting, bending, punching, welding, powder coating/painting — ensuring dimensional accuracy and finish quality.
Manage injection-moulding (IM) parts and plastic enclosure processes/vendors, including in-house or outsourced tooling, mould maintenance, and incoming quality checks.
Ensure fabricated cabinets and enclosures meet IP-rating (ingress protection), EMI/EMC shielding, and mechanical/environmental requirements for EV charger applications.
4. Assembly Operations (Mechanical, Electrical & Electronic)
Lead mechanical and electrical assembly of AC & DC chargers — wiring harness assembly, integration of MCCBs, energy meters, MCM, PLCs, contactors, relays, connectors, and other electro-mechanical hardware into fabricated cabinets.
Standardize assembly work instructions (SOPs), work-station layouts, jigs/fixtures, and torque/critical-parameter controls to ensure build consistency and safety.
Implement error-proofing (Poka-Yoke) at critical assembly steps to prevent wiring, torque, or component-mismatch errors.
Coordinate with design/engineering on BOM accuracy, ECN implementation, and assembly line balancing for new charger variants.
5. Quality Control & End-of-Line (EOL) Testing
Own the EOL testing process for finished AC & DC chargers — safety tests (hi-pot/dielectric, insulation resistance, earth continuity), functional/load testing, communication protocol testing (CAN, OCPP, Modbus as applicable), and charging-cycle validation.
Ensure in-process quality checks at every stage — SMT/PCBA, fabrication, assembly — with clear inspection standards, sampling plans, and non-conformance/CAPA processes.
Drive supplier/incoming quality (IQC) for critical bought-out components (PCBs, MCCBs, energy meters, connectors, cables, enclosures) in coordination with SQE/vendor development.
Maintain calibration schedules for test equipment, torque tools, and measuring instruments; ensure traceability and test data recording (test reports/serial number traceability) for every unit.
6. Compliance, Standards & Certification
Ensure manufacturing processes and products comply with applicable EV charging standards (e.g., IEC 61851, IS 17017, CCS/CHAdeMO/GB/T interfaces as applicable), electrical safety norms, and automotive customer-specific requirements.
Prepare for and lead OEM audits, certification audits (BIS, CE, ARAI/ICAT type-approval support), and customer quality audits; drive closure of audit findings and corrective actions.
Maintain documentation for ISO 9001 / IATF 16949 (or equivalent) quality management systems, along with EHS/ISO 14001 & 45001 compliance on the shop floor.
7. Cost, Vendor & Materials Management
Manage production budgets, manufacturing costs, scrap/rework costs, and drive cost-reduction initiatives without compromising quality or safety.
Coordinate with Supply Chain/Procurement on component availability (PCBs, MCCBs, energy meters, MCM, PLCs, connectors, sheet metal, IM parts) to avoid line stoppages.
Optimize inventory levels (WIP, RM, FG) on the shop floor through better planning, kitting, and pull-based systems.
8. Leadership, Safety & Team Development
Lead, mentor, and build a strong plant team across production, PCBA/SMT, fabrication, assembly, testing, and quality functions.
Build technical capability within the team on electronics assembly, SMT processes, electrical panel wiring, and EV charger testing.
Champion a strong safety culture — electrical safety, machine safety, ESD control, and use of PPE across all work areas.
Foster a culture of ownership, continuous improvement, and cross-functional collaboration with R&D, Quality, SCM, and Sales/Service teams.
Qualifications & Experience
B.E./B. Tech in Electrical, Electronics, Electronics & Communication, Mechatronics, or a related engineering discipline; a PGDM/MBA in Operations is an added advantage.
16–20 years of overall manufacturing experience, with significant exposure to electronics/power-electronics manufacturing (PCBA/SMT) as well as electro-mechanical/panel/enclosure assembly — ideally within EV charger, power electronics, switchgear, or automotive electrical component manufacturing.
Proven experience running a plant or a large manufacturing unit with multiple process lines (PCBA, fabrication, assembly, testing) under one roof.
Hands-on exposure to SMT/PCBA processes, sheet-metal fabrication, and EOL testing of electrical/electronic products is essential.
Experience managing OEM audits, product certifications, and automotive/EV industry quality standards.
Working knowledge of Lean Manufacturing, Six Sigma, TPM, and modern production management systems (ERP/MES).
Key Skills & Competencies
Strong technical understanding of EV AC/DC charger architecture, power electronics, and control systems (PLC-based).
Working knowledge of components such as MCCBs, energy meters, MCM, contactors, PLCs, connectors, and charger communication protocols.
Strong people leadership — able to manage a diverse, multi-skilled shop-floor team (electronics, fabrication, electrical assembly, testing).
Data-driven decision-making — comfortable working with KPIs, dashboards, and quality/production data.
Excellent problem-solving skills (RCA, 8D, fishbone/Ishikawa) and a bias for hands-on shop-floor presence.
Strong communication and stakeholder management skills to work across R&D, Quality, SCM, Sales, and senior leadership.
Commitment to safety, environmental compliance, and ethical manufacturing practices.

Work arrangement
No