Senior Manager 1 Production & R&O

Job Description – Senior Manager I / Manager II – Production & R&O (Repair & Overhaul)

Industry: Manufacturing – Energy Systems

Function: Production, Repair & Overhaul (R&O)

Position: Senior Manager I /Manager II

Reporting to: Director / Head of Operations

Location: BLR

• Job Profile

Lead and manage the Repair & Overhaul (R&O) function, ensuring efficient execution of repair, refurbishment, overhaul and reconditioning activities for energy system components and equipment. Drive operational excellence, cost optimization, quality improvement, turnaround time reduction and customer satisfaction while ensuring compliance with engineering and safety standards.

• Key Roles & Responsibilities

R&O Operations Management. Lead end-to-end Repair & Overhaul operations, including inspection, diagnosis, repair, refurbishment, testing and final release. Develop annual operating plans, budgets and capacity plans. Ensure timely completion of repair activities in line with production and customer requirements. Optimize manpower, equipment, tools and workshop utilization. Establish standard operating procedures (SOPs) and repair processes. Drive continuous improvement in repair cycle time and operational efficiency.

• Planning & Execution

Develop repair schedules based on demand, equipment availability and material readiness. Coordinate with production, engineering, quality, planning and procurement teams. Ensure availability of spare parts, consumables and critical repair materials. Establish turnaround time (TAT) commitments and monitor execution. Manage repair backlogs and prioritize critical customer requirements.

• Cost & Productivity Management

Drive repair cost optimization, material consumption and labor productivity. Identify opportunities for component refurbishment and life extension. Establish cost standards for repair activities. Manage departmental budgets and operating expenses.

• Quality & Technical Excellence

Ensure repairs meet engineering specifications and quality standards. Establish inspection, testing and validation procedures. Drive root cause analysis (RCA) and corrective/preventive actions (CAPA). Reduce repeat failures, rework and warranty-related repairs. Work closely with engineering/NPI/Quality teams to improve product reliability and repairability.

• EHS & Compliance

Ensure compliance with EHS policies and regulatory requirements. Maintain safe working practices in repair and overhaul facilities. Conduct regular safety audits and risk assessment by collaborating with EHS team.

• KPI Performance Measurement
• Qualifications & Experience
• Bachelor’s degree in electrical, Electronics or Industrial Engineering.10–15+ years of experience in manufacturing, repair, overhaul or service operations. Minimum 5 years in a managerial leadership position. Experience in energy systems, electrical equipment, industrial machinery, power systems or related manufacturing industries. Strong knowledge of maintenance, refurbishment, testing and quality systems.

• Required Skills & Competencies
• Strong operational and strategic leadership. Excellent planning and execution capabilities. Technical troubleshooting and problem-solving. Lean manufacturing and continuous improvement. Strong analytical and decision-making skills. Team development and performance management. 
•  Key Deliverables
• Establish a structured R&O operating model with clear ownership and accountability. Reduce repair turnaround time by 20–25%. Improve repair cost competitiveness through repair-versus-replace initiatives. Achieve greater than 95% on-time repair completion. Improve first-pass repair yield and reduce repeat failures. Establish a performance dashboard covering cost, quality, delivery and productivity. Develop a qualified supplier and external repair partner ecosystem. Build scalable R&O capacity to support business growth.
• Leadership Expectations
• The Senior Manager – R&O is expected to transform the repair and overhaul function into a cost-effective, quality-driven and scalable operation, supporting increased manufacturing volumes, product reliability and long-term customer satisfaction.