Job summary
The Plant Head is responsible for leading all plant operations, including production, quality, maintenance, supply chain, and new product development. The role ensures the facility operates at maximum efficiency and profitability while meeting customer expectations, maintaining a safe working environment, and driving continuous improvement initiatives.
Key responsibilities
Operational management
- Oversee the entire manufacturing process for sheet metal automotive components, from production planning and scheduling to final dispatch.
- Ensure all daily production, quality, and delivery targets are met according to company and customer standards.
- Control and manage the plant's operational budget, identifying and implementing cost-reduction measures and optimizing resource usage.
- Maintain a strong process discipline and quality orientation across all manufacturing operations to meet customer expectations and IATF 16949 standards.
- Ensure plant operations comply with all safety, environmental, and regulatory requirements.
Quality and continuous improvement
- Lead the implementation and enforcement of rigorous quality control systems to ensure product reliability and compliance with Tier 1 automotive standards.
- Drive continuous improvement initiatives by implementing methodologies such as Lean Manufacturing, Six Sigma, and 5S on the shop floor.
- Conduct root cause analysis for any production defects or deviations and implement corrective and preventive actions.
- Manage and monitor all plant quality performance, both in-house and at the customer's end.
Control and Monitor Total Plant Cost
- To monitor and Control Total Plant cost
- Daily Monitoring of all consumable consumption
- Daily monitoring of Manpower cost
- Daily monitoring of BOM cost as per actual
- To keep Overhead cost as per defined norms
- To keep COPQ to zero
- To Monitor Transportation and other costs
- 15 Days Cycle for proper compiling and sharing Data to management for analysis
MRM Review
- Daily MIS required
- Monthly Management review Meeting
Leadership and team management
- Lead, mentor, and motivate a team of department heads, engineers, supervisors, and workers to ensure high performance and operational excellence.
- Foster a culture of accountability, teamwork, and continuous learning within the plant.
- Manage and coordinate all aspects of the workforce, including recruitment, training, performance management, and resolving employee issues.
- Maintain healthy industrial relations with plant personnel and liaise with government authorities as necessary.
Supply chain and client management
- Oversee supply chain logistics, including inventory management and procurement, collaborating with purchasing teams to ensure efficient and cost-effective sourcing of materials.
- Build and maintain strong relationships with key stakeholders, including clients and suppliers.
- Ensure on-time delivery of products and respond effectively to customer issues.
Strategy and business development
- Contribute to business growth by scouting for new opportunities and supporting new product development (NPD) projects, ensuring preparedness for new customer production lines.
- Develop and execute strategic plans to meet long-term business objectives.
- Present operational reports and performance metrics to senior management.
Qualifications and skills
Education and experience
- A bachelor's degree in Mechanical Engineering, Manufacturing, Industrial Engineering, or a related field is required.
- 20+ years of experience in high-volume manufacturing within the automotive, fabrication, or sheet metal industry, with at least 5 years in a senior leadership role.
- Mandatory experience with sheet metal processes, including a press shop, fabrication, welding, CNC, and assembly.
- Proven experience as a Profit Centre Head or Plant Manager for a medium to large manufacturing operation.
Technical skills
- Deep knowledge of sheet metal fabrication processes, quality systems (IATF 16949), and standards like ISO 9001 and ISO 14001.
- Expertise in lean manufacturing principles, such as 5S and TPM (Total Productive Maintenance).
- Familiarity with quality tools like APQP, PPAP, and FMEA.
- Proficiency in root cause analysis and troubleshooting.
- Understanding of ERP systems for effective supply chain and resource management.
Management and soft skills
- Exceptional leadership, team management, and problem-solving abilities.
- Excellent planning, organizational, and strategic thinking skills.
- Strong communication and interpersonal skills for interacting with all levels of the organization and external stakeholders.
- Ability to work under pressure, meet tight deadlines, and adapt to changing demands.
