Caparo Engineering Hiring – Production Assistant Manager / Deputy Manager (Machine Shop)

📍 Location: Sunguvarchatram – Kanchipuram, Tamil Nadu
🏭 Industry: Automotive Parts Manufacturing (MNC)
💼 Position: Assistant Manager / Deputy Manager – Production (Machine Shop)
💰 Salary: No Bar for the Right Candidate
🎓 Qualification: DME / BE / BTech
🕒 Experience: 10–15 Years (Machine Shop)

🔧 Job Description / Key Responsibilities

1. Machine Shop Operations & Manpower Management

• Strong knowledge of machine shop manpower planning and execution

• Daily production planning, monitoring, and output control

2. CNC & Special Machine Expertise

• Programming skills in CNC Turning & Milling

• Experience with VMC, VTC, SPM, tailor-made assembly machines, DAQ systems, laser machines

3. Quality Systems & Documentation

• Strong understanding of TS, IMS, QMS

• Experience in documentation, audits, and compliance

4. Continuous Improvement Tools

• Active user and champion of 7 QC Tools, TPM, Six Sigma, 5S

• Strong problem-solving approach using 8D, CAPA, PDCA, 5W2H tools

5. CAD/CAM & Tooling Knowledge

• Proficiency in CAD & CAM

• Fixture design and tooling (except casting products)

6. Cost Control & Kaizen

• Good control over variable cost

• Experience in driving cost savings through Kaizen, QC Story, DOE

7. Process & Quality Knowledge

• Hands-on knowledge of control plans (CP), PFMEA, quality documents

• Experience in reading/analyzing CMM reports

8. Software Skills

• SAP knowledge

• MS Office, especially PowerPoint for reporting

🏭 Facilities Provided

• Food

• Transport

📩 How to Apply

If interested, please contact:

Vedhachalam R
Plant HR & Admin – Aluminium Foundry
📱 WhatsApp Only: +91 8098548526
📧 Email: vedhachalam.rajendiran@caparo.co.in

Top Interview Questions & Professional Answers

1. What is your experience in managing machine shop operations?

Answer:
I have managed machine shop operations including manpower planning, shift allocation, production scheduling, machine loading, output monitoring, tool life monitoring, and production quality adherence. I focus on maintaining daily targets while ensuring safety, productivity, and process stability.

2. How do you plan and manage manpower in a machine shop?

Answer:
I prepare a manpower matrix based on skill levels, machine criticality, and production volume. I ensure proper skill rotation, training, and load balancing. I also plan for absenteeism, overtime control, and operator capability building.

3. What is your experience with CNC turning and milling machines?

Answer:
I have hands-on experience in CNC programming, tooling selection, offsets, cycle-time optimization, fixture setup, and troubleshooting for Turning Centers, VMC, VTC, SPMs, and laser machines. I regularly optimize tool paths and machining parameters to improve efficiency and product quality.

4. How do you ensure quality systems compliance (TS/IMS/QMS)?

Answer:
I maintain updated control plans, PFMEA, SOPs, and process documents. I ensure effective implementation of TS 16949, QMS, and IMS requirements. I also coordinate for audits, corrective actions, and documentation control.

5. Explain your approach to problem-solving using 8D methodology.

Answer:
I follow:

1. D1–Team formation
2. D2–Problem description
3. D3–Containment actions
4. D4–Root Cause Analysis (5 Why, Fishbone)
5. D5–Corrective action proposal
6. D6–Corrective action implementation
7. D7–Preventive action
8. D8–Closure & recognition
   This ensures sustainable elimination of issues.

6. How do you perform root cause analysis (RCA)?

Answer:
I use 5 Why Analysis, Fishbone Diagram, parameter matrix, and why-why analysis. I validate root causes using data, testing, and cross-functional reviews before implementing CAPA.

7. What is your experience with PFMEA and how do you use it?

Answer:
I prepare and review PFMEA to identify potential failures, evaluate RPN, and develop preventive actions. During new product development or process changes, I ensure PFMEA is updated and linked correctly with control plans and SOPs.

8. How do you manage cost control in machine shop operations?

Answer:
I focus on tool life improvement, cycle-time reduction, scrap reduction, energy-saving initiatives, and manpower optimization. I drive Kaizens, DOE, and QC Story for consistent cost savings.

9. How do you ensure machine utilization and reduce downtime?

Answer:
I monitor OEE parameters—Availability, Performance, and Quality. I coordinate with maintenance for preventive maintenance, ensure tool presetting, plan raw material availability, and adopt 5S + TPM methodologies to eliminate minor stoppages.

10. Explain your experience with CAD & CAM systems.

Answer:
I use CAD/CAM for tool path generation, fixture design, simulation, and machining optimization. I also coordinate with design and tooling teams to improve manufacturability and reduce non-value-added operations.

11. What steps do you take to maintain variable cost control?

Answer:
I control tool consumption, reduce rejections, optimize coolant use, improve energy efficiency, and implement Kaizen and DOE-based improvements. Regular cost monitoring and review meetings help sustain savings.

12. How do you manage production quality in machine shop operations?

Answer:
I ensure process adherence through control plans, in-process inspection, SPC monitoring, tool wear checks, and operator training. I use CMM reports to validate dimensions and improve process capability.

13. What is your experience with SAP in production management?

Answer:
I use SAP for production order creation, material issuance, machine loading, reporting confirmations, inventory tracking, rejection recording, and generating MIS reports.

14. How do you drive continuous improvement in your machine shop?

Answer:
I lead Kaizen events, implement TPM pillars, perform QC Story projects, monitor tool life, review CTQ parameters, and drive daily Gemba walkthroughs to identify improvement opportunities.

15. Why should we hire you for this role?

Answer:
I bring strong technical expertise in CNC machining, quality systems, cost reduction, CAD/CAM, PFMEA, and production planning. I have a proven track record of improving productivity, reducing cost, and ensuring high-quality output in an automotive machine shop environment. My leadership and problem-solving skills make me a strong fit for Caparo’s growth-oriented environment.