Job Description for Plant Head Role Title / Designation: Plant head (Operation head) Reporting to: Managing Director (MD) Purpose Of the Role : 1. To standardize the production process for each alloy by leveraging core metallurgical expertise, ensuring consistency and efficiency in manufacturing. 2. To analyze customer requirements to determine the feasibility of producing the desired product within the available manufacturing facility, utilizing deep metallurgical knowledge . 3. To optimize production workflows , manage resources, and ensure that production goals are achieved while maintaining world-class quality standards in each product and the overall production process. 4. To strive to reach the highest possible technical limit values ( TLVs ) of KPIs such as manufacturing facility, OEE and rejection rates. Key Responsibilities: 1. Ensure that production processes (standard operating procedures - SOP ) and parameters are well defined for all kind of alloys for all workstations from melting to finishing. 2. Work closely with the Quality (lab) team to develop new alloys and document all the process & parameters in the form of SOP. 3. Understand customer requirement w.r.t. alloys specifications, properties, production process and standards from end customer and pass the information down the line to meet the customer specification and to move towards zero rejections eventually. 4. Develop & implement the formats for capturing all the data generated at all workstations related to alloy type, start & end time, operating parameters (e.g. temperature), resource allocation & utilization, machine availability & utilization, material consumption etc. Also ensure all employees adhere 100% to these formats. 5. Conduct training sessions of all working employees (workers, operators, supervisors, HODs) with the help of defined SOPs & set training schedules to ensure all manual errors w.r.t. quality are eliminated completely. 6. Facilitate the creation and execution of production route cards for each heat, ensuring traceability and alignment with customer specifications. 7. Oversee the entire production process , ensuring material and resource availability from raw materials (scrap, alloying elements) to melting, casting, machining, and finishing processes. 8. Develop and implement a production plan to meet customer delivery timelines (for 100% OTIF ). Make necessary modifications in production plan if the deliveries get delayed w.r.t. order priority. 9. Generate essential daily/weekly/monthly MIS reports (Management Information system) on time & without error using the data captured in formats if required design new formats. 10. Analyze production & quality data to identify the losses/rejections/rework trends & their causes. Prepare action plans to reduce the losses in terms of quality, availability & performance. 11. Achieve set performance targets (KPIs) and conduct regular evaluations with production team & implement best practices to reduce gap between the current performance & KPI targets. 12. Use lean manufacturing principles ( Poka-yoke, 5S, OEE, TQM, TPM etc.) and continuous improvement techniques ( Kaizen ) to enhance production effectiveness & efficiency. 13. Design Organizational structure end to end including departments structure. Identify & arrange the resource requirement (manpower, equipment & tools, materials etc.) and allocate them appropriately to ensure highest productivity. 14. Ensure machine abnormalities are rectified by the maintenance team urgently to reduce the machine downtime and to increase the availability & performance . 15. Implement planned maintenance ( preventive maintenance, CLRI ) of the equipment to increase the MTBF and to reduce MTTR . Maintain spare parts and consumable inventory adequately. 16. Augment CapEx requirement and evaluate the ROI period and submit to management. 17. Upgrade existing manufacturing process to enhance reproducibility & repeatability of product/process to achieve production first time right without trial. 18. Provide suggestion to management to improve organization culture, policies, and work environment periodically. 19. Ensure zero safety incident by complying with health and safety regulations and promote a culture of safety (PPEs, helmets, safety cover for high RPM machines etc.). 20. Collaborate with the sales and business development teams to generate new orders and expand the company's customer base. Required Experience: 1. Bachelors degree in Metallurgical Engineering , or a related field. A Masters degree or relevant certifications is a plus. 2. Minimum of 15 years of experience in a Copper alloy manufacturing, with at least 5 years in a leadership role. Required Skill-set & Preferences: 1. In-depth expertise in metallurgical processes especially in copper alloys manufacturing. 2. In-depth knowledge of EN, IS & BIS standards. 3. Strong leadership and team management skills. 4. Excellent problem-solving and analytical abilities. 5. Familiarity with lean manufacturing and continuous improvement methodologies. 6. Strong communication and interpersonal skills.
