Purpose of the Role
The Plant Head will have end-to-end responsibility for the safe, efficient and profitable operation of the plant, covering production, maintenance, quality, safety, cost, manpower, industrial relations, statutory compliance and operational excellence.
The incumbent will be responsible for achieving production and financial targets while continuously improving productivity, yield, quality, equipment reliability, energy efficiency and manpower effectiveness.
Job Responsibilities (KRA)
A. Production & Operations
- Own the complete plant production plan and execution.
- Achieve production targets in terms of volume, quality, product mix and timelines.
- Maximize plant capacity utilization and throughput.
- Improve OEE, productivity and process efficiency.
- Identify and eliminate production bottlenecks.
- Optimize manpower, machinery and material utilization.
- Ensure adherence to production schedules and customer commitments.
- Establish daily production review mechanisms.
B. Cost & Productivity
- Drive reduction in conversion cost per MT.
- Control energy, fuel, consumables, manpower and maintenance costs.
- Improve material yield and reduce process losses.
- Reduce scrap, rejection and rework.
- Establish plant-level cost benchmarks.
- Identify and implement annual cost-saving initiatives.
- Improve overall plant EBITDA contribution.
C. Maintenance & Reliability
- Ensure preventive and predictive maintenance systems.
- Improve equipment availability and reliability.
- Minimize breakdowns and unplanned downtime.
- Monitor MTBF and MTTR.
- Develop critical-spares strategy.
- Ensure timely maintenance shutdowns.
- Drive equipment modernization and automation wherever commercially viable.
D. Quality
- Ensure compliance with applicable BIS, ISO and customer specifications.
- Reduce rejection, rework and customer complaints.
- Implement root-cause analysis for recurring quality issues.
- Drive "Right First Time" manufacturing.
- Establish quality KPIs for every production department.
- Work closely with customers/Sales on quality-related issues.
E. Raw Material & Inventory
- Ensure optimum availability of raw materials and consumables.
- Monitor material yield and consumption norms.
- Reduce excess and slow-moving inventory.
- Control WIP and finished-goods inventory.
- Coordinate with Procurement, PPC and Commercial teams.
- Ensure proper material accounting and reconciliation.
F. Safety & Environment
- Establish Zero Accident / Zero Harm culture.
- Ensure strict compliance with EHS standards.
- Conduct regular safety audits and toolbox talks.
- Investigate accidents and near misses and implement corrective actions.
- Ensure statutory environmental compliance.
- Monitor waste, emissions, water and energy consumption.
- Ensure emergency preparedness and disaster-management systems.
G. Industrial Relations & Manpower
- Ensure discipline and grievance-handling mechanisms.
- Optimize permanent and contract manpower.
- Improve manpower productivity.
- Work closely with Plant HR on absenteeism, attrition, engagement and workforce planning.
- Ensure compliance with applicable labour laws and employment regulations.
H. People & Leadership
- Lead the Plant Leadership Team.
- Develop Production, Maintenance, Quality, EHS and other functional heads.
- Establish individual KPIs and accountability.
- Build a high-performance culture.
- Develop succession plans for critical positions.
- Identify training and capability-building requirements.
- Promote cross-functional collaboration.
I. Continuous Improvement
Drive implementation of:
Lean Manufacturing, TPM, Kaizen, 5S, Six Sigma, OEE improvement, Energy conservation, Waste reduction, Automation, Digital manufacturing/MIS, Benchmarking and best practices
Job Requirements (KPI)
- 15–20+ years of experience in steel/metals/manufacturing.
- At least 5–8 years as Plant Head / Unit Head / Senior Operations Head.
- Experience managing large manufacturing operations.
- Strong exposure to steel pipes, tubes, rolling mills, billets, DRI, galvanizing or related steel operations preferred.
Qualification: B.E./B.Tech in Mechanical / Metallurgical / Production / Electrical Engineering & MBA/PGDM will be an advantage
