General Manager Process / Production

General Manager Process / Production

The role ensures achievement of production targets, process optimization, cost efficiency, safety compliance, and equipment reliability through effective leadership and continuous process improvement initiatives.

Key Responsibilities:

1. Plant Operations

• Lead daily

  production planning and execution

  to meet operational targets and business goals.
• Monitor equipment status and coordinate with

  maintenance teams

  to implement

  predictive and preventive maintenance schedules

  to enhance reliability and minimize downtime.
• Review

  process parameters

  and initiate corrective measures to ensure process stability and optimization (e.g., installation of buffer plates to regulate pressure).
• Supervise

  corrective and preventive measures

  such as periodic refractory and brick line replacement to prevent equipment failure.
• Conduct

  root cause analyses (why-why analysis)

  for unplanned stoppages and ensure timely corrective action.
• Analyze

  daily process log sheets

  , equipment performance data, and operational KPIs (e.g., fan RPMs, grinding media wear, baghouse performance, and brick condition).
• Implement

  process improvement projects

  and

  technology upgrades

  to enhance productivity, quality, and cost efficiency.
• Collaborate closely with

  internal stakeholders

  (Maintenance, Quality, RMH, Civil, Safety, etc.) and engage with

  external stakeholders

  (vendors, OEMs, contractors) as required.

2. Process Excellence

• Identify and execute

  process optimization and cost reduction initiatives

  across operations.
• Drive

  manpower, cost, and inventory optimization

  to improve plant performance and efficiency.
• Champion

  continuous improvement methodologies

  such as

  Six Sigma

  ,

  Total Productive Maintenance (TPM)

  , and

  Lean Manufacturing

  .
• Optimize

  power utilization, emission control, and production efficiency

  within defined quality and environmental norms.
• Ensure

  maximized uptime

  of key plant equipment (kilns, mills, crushers) through proactive monitoring and interventions.
• Lead

  project execution and commissioning activities

  , ensuring adherence to time, cost, and safety standards.

3. Employee Engagement & Safety

• Foster a

  zero-incident safety culture

  , ensuring strict adherence to all

  EHS (Environment, Health & Safety)

  standards and regulatory norms.
• Promote a culture of

  continuous improvement, accountability, and collaboration

  across the production team.
• Enhance

  employee engagement

  , build team capability, and maintain a

  positive work environment

  through coaching and mentoring.
• Drive initiatives to strengthen

  safety awareness, housekeeping, and sustainability practices

  at the plant.

Education & Qualifications:

• B.E. / B.Tech.

  in Mechanical, Chemical, or Production Engineering from a reputed Tier 1 / Tier 2 institution.

• Postgraduate qualification (MBA / PGDM)

  in Operations or Industrial Management (preferred).

Experience:

• 18-22 years

  of progressive experience in

  cement manufacturing or related process industries

  .
• Proven track record in handling

  large-scale process operations

  ,

  plant optimization

  ,

  shutdown planning

  , and

  project commissioning

  .
• Strong exposure to

  Cement Manufacturing Value Chain

  and in-depth knowledge of

  kiln, raw mill, and cement mill processes

  .
• Hands-on experience implementing

  process excellence frameworks

  such as

  Six Sigma

  ,

  TPM

  ,

  Kaizen

  , or

  Lean

  .