Plant Head

Greetings from VARROC !

Varroc Group

With 36 world-class manufacturing facilities, 7 R&D centers and over 6500 employees across 8 countries, Varroc is on an exponential growth trajectory, clocking net revenues in excess of 58,000 million in FY 22.

With 3 decades of relentless commitment to excellence and value-based performance, Varroc offers the best design solutions that gives its customers a competitive edge in their markets.

Website: https://varroc.com/

PLANT HEAD

We are looking for a seasoned professional with full time Engineering Degree having at least 15-20 years of strong experience to the following aspects of this Job role -

• Strong manufacturing experience with a

  Tier 1 Automotive

  Companies
• Exposure to Automotive 2W / 4W OEM Customers -

  MANDATORY

• Exposure to manufacturing of Automotive

  Electrical / Electronics / Lighting / Polymer

  Components & Manufacturing Process -

  MANDATORY

• Experience in managing teams -

  MANDATORY

JOB PURPOSE:

Lead production planning and execution for the assigned plant; Ensure and provide inputs for improvement project planning and execution, raise the capex requirements; Review metrics to ensure achievement of set production objectives; Coordinate with other departments such as maintenance, quality, improvement, etc. to align and remove roadblocks.

PRINCIPAL ACCOUNTABILITIES:

1. Production Planning

Understand the targets set for sales, variable cost, fixed cost, etc. set for Business Development

Draw own functional priorities and participate in the cross functional team to convert these targets to relevant targets for production, Propose PPM targets, PQCD cost, etc. at the beginning of year to ensure EBITDA objectives are met

Develop plans to ensure minimum production cost in line with the business plan to achieve the PQCD targets by ensuring continuous improvement.

Conduct discussions with the key customer Purchase and PPC to finalize the man and material planning for the coming month, identify and provide suggestions for resolution of issues.

Execute the production plan as per the PPC guidelines to meet the Customer schedule.

2. Improvement Projects

Define projects in line with the overall improvement targets for production, maintenance, etc.

Should be able to work on greenfield projects, major plant refurbishment.

Provide inputs to ME team on project planning and execution; Analyze and identify lines with opportunities to improve / reduce cycle time, etc. Provide ideas and brainstorm with the improvement ME team on opportunities and scope for improvements in manufacturing processes through process elimination, process merging, changes in layout etc

Raise monthly capex requirements for projects, share input on manpower savings with HR and other factors impacting P&L (fixed/variable cost) for review by Plant Head.

Monitoring Kaizen, 5s & TPM training & train employees for multi machining & multi skilling.

Drive major plant productivity projects

3. IHR & Customer Complaints

Monitor & Reduce IHR level by analyzing the product and process defects and taking corrective action by improving production process and deploying the same horizontally.

Review day to day production process for rejection monitoring (process wise & product wise) to identify top defect for down the line Implementation of corrective and preventive actions.

Monitoring SPC (Statistical Process Chart) & PQC (Process Quality Chart) repots to correct production process.

4. Safety

Monitoring implementation of EHS guidelines, implementing various EHS systems, monitoring strict usage of PPEs.

Monitoring, implementation & adherence to health and safety procedures & documenting near miss, may happens, unsafe condition to take necessary actions to prevent accidents.

Keeping the records of near miss accident & implement near miss kaizens to ensure zero accident & build safety culture.

Monitoring for audit compliance & taking corrective actions to clear nonconformities.

5. Internal Audit and Documentation

Monitor internal audit for auditing adherence to Safety, TPM,5s at the shop floor.

Ensure completeness of documents for IATF, Customer & other external audits

Workout and implement SOPs (Standard operating procedures), OPL (One Point lesson) for production process.

Monitoring Employees Skill matrix & Preparing Production MIS.

Document preparation for IATF, OSHAS, Customer & other external audits.

6. Review and execution

Coordinate and seek alignment across functions/ departments such as maintenance, purchase, store, HR, etc. to achieve the set targets

Anticipate and resolve escalated issues, remove roadblocks synergies and ensure overall targets are achieved

Analyze, consolidate and put up manpower requirements to the HR department

Closely monitor early failure report (IFR), inhouse rejection cost (IHR), scrap cost to achieve set targets

7. Team development

Establish individual performance expectations and regularly review individual performance of the team

Identify and create development opportunities for team members to enhance functional knowledge

Plan for second line development and scale up, provide additional responsibilities for team from time to time

QUALIFICATION:

Minimum Qualification required: BE / B.Tech (Electronics / Polymer preferred)

MBA / PG in Operations / SCM will be an added advantage

WORK EXPERIENCE:

Minimum 15-20 years of experience of leading a plant / manufacturing unit / large scale production

In-depth knowledge of Electrical/Electronics/Lighting/Polymer product and its manufacturing processes (EMS & PAINTING)

Overall P&L responsibility for the plant, hands-on with top-line, bottom-line, EBITDA, ROCE etc

Experience of production management of similar products categories (Automotive Products/Components)

Out Station applicants need to relocate to Aurangabad / Pune

screening questions