Job Summary:

The Plant Head (HOD) is a critical leadership role responsible for overseeing all aspects of plant operations at the designated manufacturing location (Loni or Dhaulana). This individual will be accountable for ensuring operational excellence, optimizing resource utilization, maximizing production efficiency, maintaining high standards of quality, safety, and environmental compliance, and driving overall business success. The Plant Head will lead a team of managers and supervisors, fostering a culture of continuous improvement and collaboration.

Key Responsibilities:

1. Production Management:

- Develop and implement strategic production plans and schedules to meet production targets, customer demands, and delivery timelines.

- Oversee the entire production process, from raw material input to finished goods output, ensuring smooth and efficient operations.

- Monitor production output, identify bottlenecks, and implement corrective actions to optimize productivity and minimize downtime.

- Analyze production data and key performance indicators (KPIs) to identify areas for improvement and implement effective solutions.

- Ensure adherence to established production procedures and standards.

- Manage and control production costs, including raw materials, labor, and overheads, to maximize profitability.

- Implement and maintain efficient inventory management systems for raw materials, work-in-progress, and finished goods.

- Lead and motivate the production team to achieve production goals and maintain a high level of performance.

2. Quality Assurance & Control:

- Establish and maintain a robust quality management system (QMS) in compliance with industry standards and company policies.

- Implement and monitor quality control procedures throughout the production process to ensure products meet specified quality standards and customer requirements.

- Oversee quality inspections and testing of raw materials, in-process goods, and finished products.

- Analyze quality data, identify root causes of defects, and implement corrective and preventive actions (CAPA).

- Ensure proper documentation of quality control processes and results.

- Foster a culture of quality awareness and continuous improvement within the production team.

3. Machine Utilization & Maintenance:

- Develop and implement a comprehensive maintenance program (preventive, predictive, and reactive) to ensure optimal utilization and longevity of plant machinery and equipment.

- Oversee the maintenance and repair of all plant equipment, minimizing downtime and maximizing operational efficiency.

- Manage the maintenance budget and ensure cost-effective maintenance practices.

- Ensure compliance with safety regulations related to machinery operation and maintenance.

- Coordinate with external vendors for specialized maintenance services and equipment upgrades.

- Monitor machine performance and identify opportunities for improvement and upgrades.

4. Workplace Management & Safety:

- Establish and maintain a safe and healthy work environment in compliance with all applicable safety regulations and company policies (e.g., EHS).

- Implement and enforce safety procedures and protocols to prevent accidents and injuries.

- Conduct regular safety audits and inspections to identify and address potential hazards.

- Lead and manage safety training programs for all plant personnel.

- Investigate accidents and incidents, implement corrective actions, and promote a strong safety culture.

- Ensure the plant is organized, clean, and well-maintained.

5. Data & Inventory Management:

- Implement and utilize data collection and analysis systems to track production metrics, quality data, and inventory levels.

- Analyze data to identify trends, optimize processes, and make data-driven decisions.

- Oversee inventory management processes to ensure accurate stock levels, minimize waste, and prevent stockouts.

- Implement and manage inventory control measures to prevent losses and discrepancies.

6. Resource Optimization:

- Optimize the utilization of all plant resources, including manpower, materials, equipment, and energy.

- Identify and implement cost-saving initiatives to improve operational efficiency and reduce waste.

- Manage the plant budget and ensure adherence to financial targets.

- Implement lean manufacturing principles and other process improvement methodologies to enhance efficiency.

7. Customer Complaint Resolution:

- Investigate and resolve customer complaints related to product quality or delivery issues in a timely and effective manner.

- Implement corrective actions to prevent recurrence of similar complaints.

- Maintain effective communication with the sales and customer service teams regarding customer feedback.

8. Manpower Planning & Development:

- Plan and forecast manpower requirements for the plant, ensuring adequate staffing levels to meet production demands.

- Recruit, train, and develop plant personnel, fostering a skilled and motivated workforce.

- Conduct performance evaluations and provide feedback to team members.

- Identify training needs and implement training programs to enhance employee skills and knowledge.

- Promote a positive and collaborative work environment.

9. Process Improvement & Compliance:

- Continuously identify opportunities for process improvement and implement best practices to enhance efficiency, quality, and safety.

- Ensure compliance with all relevant regulatory requirements, environmental regulations, and company policies.

- Stay updated on industry trends and advancements in manufacturing technology.

10. Stakeholder Coordination & Reporting:

- Coordinate effectively with other departments, including sales, marketing, procurement, and finance.

- Prepare and present regular reports on plant performance, production output, quality metrics, and other key indicators to senior management.

- Communicate effectively with all stakeholders, both internal and external.

- Education: Master's degree in Operations Management, Business Administration, or a relevant field is highly desirable.

Qualifications and Skills:

- Proven track record of at least 20 years in a heavy manufacturing environment, with a strong preference for experience in the steel manufacturing industry.

- Demonstrated leadership and management skills, with the ability to motivate and develop a large team.

- Strong understanding of production processes, quality control methodologies, and maintenance practices in a heavy manufacturing setting.

- Excellent analytical and problem-solving skills, with the ability to identify root causes and implement effective solutions. -

- Sound knowledge of safety regulations and best practices in a manufacturing environment.

- Proficiency in data analysis and reporting.

- Excellent communication, interpersonal, and presentation skills.

- Strong decision-making abilities and a results-oriented approach.

- Familiarity with lean manufacturing principles and other process improvement methodologies.

- Knowledge of inventory management systems and best practices.

- Ability to work effectively under pressure and meet deadlines.

- Proficiency in relevant software applications (e.g., ERP systems, MS Office Suite).