Plant Head (DGM/GM) - Foundry

Purpose of the Role 
The Plant Head shall be responsible for the overall leadership, operational efficiency, profitability, safety, quality, delivery performance, and strategic growth of the foundry business. The incumbent will provide end-to-end direction for manufacturing operations and ensure achievement of business objectives through effective management of Production, Product development, Quality, Maintenance, Commercial, Supply Chain, HR, and EHS functions.

The role requires a strong techno-commercial leader with proven experience in ferrous foundry operations, manufacturing excellence, cost optimisation, business planning, and people leadership.

Job Responsibilities (KRA)

 Production Performance:  Production Volume, Capacity Utilization, Productivity
 Financial Performance: EBITDA, Conversion Cost/MT, Budget Achievement
 Product Development : High Chrome, Sinter cast, Bimatelling Casting, Insert based castings, Special Purpose Casting
 Quality Performance: Internal Rejection %, Customer Rejection PPM, COPQ
 Delivery Performance: OTIF, Dispatch Adherence, Lead Time
 Safety Performance: LTIFR, Reportable Incidents, Audit Compliance
 Maintenance Performance: OEE, MTBF, MTTR, Breakdown Hours
 Inventory Management : Inventory Turns, Working Capital Days
 People Development: Attrition %, Training Hours, Employee Engagement
 Continuous Improvement: Cost Saving Projects, Productivity Improvement Projects

Technical Expertise Required

Foundry Operations

• Ferrous Foundry Operations, Steel Castings, High Chrome Castings, Manganese Steel Castings, Alloy Steel Castings, Sinter casting, Bi metallic casting and Wear resist castings.

Process Knowledge

• Induction Furnace Operations, No-Bake Sand Systems, Shell Moulding Process, Core Making Technologies, Heat Treatment Processes, Fettling & Finishing Operations, Casting Yield Optimization, Defect Analysis & RCA and Process Development & Standardization

Quality Systems

• ISO 9001,ISO 14001, NDT Methods (UT, RT, MPI, PT) and Metallurgical Testing & Failure Analysis

Financial Management

• Profit & Loss Accountability, Annual Business Planning, Budgeting & Forecasting, Cost Control & Profitability Improvement, Capital Investment Evaluation (CAPEX)

Costing & Pricing

• Product Costing, Casting Cost Analysis, RFQ Evaluation, Manufacturing Cost Optimization

Business Development Support

• New Product Introduction (NPI), Customer Technical Reviews, Cost Competitiveness Improvement, Market Development Support

Job Requirements (KPI)

Educational Qualification

• B.E. / B.Tech in Mechanical Engineering / Metallurgical Engineering or Foundry Technology from Reputed Engineering College 
• MBA (Operations / Production Management) or PG Diploma in Foundry Technology

Experience Requirements

• Minimum 18-25 years of experience in Foundry / Heavy Engineering Manufacturing.
• At least 5 years in a senior leadership position such as Plant Head, Foundry Head, Operations Head, Manufacturing Head or Business Unit Head.
• Experience in handling large-scale ferrous foundry operations.
• Experience in Mining, Cement, Industrial or Wear Resistant Castings.
• Experience managing large manpower strength (300+ employees).
• Exposure to ERP systems such as SAP