Manufacturing & ProductionFull time
23 Oct
Plant Head
Halol, India
~30 Lac
Full time
Job Title
Plant Head
Department
Operations / Manufacturing
Reports To
Business Head
Location
Halol, Gujarat
Position Type
Full-time, On-site
Plant Size
Current manpower strength of approximately 50, including 10 staff
Variable Pay
KPI-linked variable pay; component and targets to be determined after completion of the probation period
1. Job Purpose
The priority is a hands-on plant leader with technical understanding of glass-fibre reinforcement materials and technical fabrics—particularly multiaxial glass fibre, glass woven roving and related glass-fibre products.
The Plant Head will be responsible for the overall management, budgeting, and performance of the plant, including production, product development, quality, maintenance, safety, inventory control, dispatch, people management, operational efficiency, and financial performance.
The role requires strong knowledge of manufacturing processes involving multiaxial glass fibre, glass woven roving, glass fibre, and technical fabrics, together with the ability to establish structured systems, optimise resources, develop teams, and achieve the organisation’s operational and business objectives.
The objective is to ensure safe, efficient, and cost-effective plant operations while maintaining product quality, meeting customer commitments, driving continuous improvement, and supporting the company’s future growth.
2. Key Responsibilities
A. Plant Operations and Production Management
· Oversee the overall functioning of the plant and ensure smooth, safe, and efficient day-to-day operations.
· Develop and implement production plans aligned with customer requirements, delivery commitments, and business priorities.
· Monitor production output, productivity, machine utilisation, material consumption, yield, cycle times, overall equipment effectiveness (OEE), and other operational metrics.
· Ensure optimal utilisation of manpower, machinery, raw materials, utilities, and other resources.
· Identify production bottlenecks and implement corrective actions to improve throughput, productivity, and reduce downtime.
· Establish standard operating procedures (SOPs) and ensure adherence to defined processes, work instructions, and production schedules.
· Ensure effective shift handovers, shift-wise production reporting, regular production reviews, and accountability at all levels.
· Coordinate with procurement, stores, quality, sales, and other departments to ensure uninterrupted production.
· Ensure timely order execution and delivery of products as per agreed specifications and schedules.
B. Technical Knowledge and Product Development
· Maintain a strong understanding of glass fibre, multiaxial glass fibre, glass woven roving, technical fabrics, their manufacturing processes, and applications.
· Understand fabric properties, material specifications, product characteristics, and factors affecting product performance.
· Work with technical and production teams to develop new products and improve existing products.
· Evaluate new materials, manufacturing techniques, and process improvements to enhance product quality, performance, and material utilisation.
· Support product trials, process validation, troubleshooting, and implementation of new product specifications.
· Coordinate with customers and internal stakeholders to understand technical requirements and translate them into manufacturing solutions.
· Drive continuous improvement in product design, manufacturing processes, and material utilisation.
C. Quality Management
· Ensure products meet defined quality standards, customer specifications, and applicable requirements.
· Establish and monitor quality control systems throughout the manufacturing process.
· Define in-process inspections, testing protocols, process parameters, and final product release criteria in coordination with the quality team.
· Investigate defects, identify root causes, and implement corrective and preventive actions (CAPA).
· Minimise rejection, rework, material wastage, and customer complaints.
· Maintain batch records, inspection reports, product traceability, and compliance with established quality procedures.
· Support internal audits, customer audits, supplier-quality initiatives, and applicable certification requirements.
· Promote quality ownership and continuous improvement across the plant.
D. People and Team Management
· Lead, motivate, and develop production, technical, maintenance, and support teams.
· Establish clear roles, responsibilities, reporting structures, and performance expectations.
· Set departmental KRAs and KPIs and regularly review individual and team performance.
· Build a culture of accountability, discipline, teamwork, and continuous learning.
· Identify skill gaps and organise appropriate training and development initiatives.
· Plan manpower requirements and shift schedules, including contract workforce, and coordinate with HR on attendance, discipline, and employee relations.
· Support workforce planning, manpower optimisation, succession planning, and employee engagement.
· Address employee concerns and resolve operational conflicts effectively.
· Develop a strong second line of leadership to ensure operational continuity and scalability.
E. Financial Management and Cost Control
· Prepare and manage plant operating budgets in line with business objectives.
· Monitor manufacturing costs, production expenses, labour costs, energy consumption, and material utilisation.
· Drive cost-reduction initiatives without compromising product quality, safety, or delivery commitments.
· Monitor and minimise scrap, wastage, rework, and other operational losses.
· Review plant performance against budgets and financial targets and implement corrective measures where required.
· Evaluate capital expenditure requirements for machinery, equipment, capacity enhancement, automation, and process improvement.
· Track key operational and financial performance indicators and submit periodic reports to management.
F. Maintenance, EHS, and Compliance
· Ensure effective preventive and predictive maintenance of plant machinery and equipment, and minimise breakdowns and unplanned production interruptions.
· Ensure availability and reliability of essential utilities, including electrical systems, compressed air, water, and ventilation.
· Ensure compliance with applicable statutory requirements, labour laws, factory and fire safety regulations, workplace safety standards, and environmental regulations.
· Promote safe working practices and ensure appropriate use of personal protective equipment (PPE), machine guarding, permit-to-work systems, lockout/tagout (LOTO), and safe material-handling practices.
· Investigate incidents, near misses, and unsafe conditions and implement corrective and preventive actions.
· Ensure safe storage, handling, and disposal of chemicals, resins, solvents, glass fibres, and other hazardous materials, wherever applicable.
· Monitor waste management, emissions, effluent, energy consumption, and other relevant environmental parameters.
· Maintain good housekeeping, workplace organisation, and disciplined plant operations.
· Ensure effective administration of factory premises, infrastructure, utilities, and support services.
· Coordinate with relevant teams to address safety risks, maintenance issues, and compliance gaps.
G. Planning, Reporting, and Continuous Improvement
· Establish a structured approach to plant planning, execution, monitoring, and reporting.
· Define and monitor KPIs including production efficiency, productivity, OEE, rejection rates, wastage, delivery performance, and cost per unit.
· Prepare regular plant performance reports and present key updates, challenges, and improvement plans to management.
· Establish daily, weekly, and monthly performance reviews supported by production dashboards and loss analysis.
· Analyse operational data to identify improvement opportunities and support fact-based decision-making.
· Implement Lean Manufacturing, TPM, Kaizen, 5S, and other appropriate methods to improve efficiency, quality, capacity, and cost competitiveness.
· Ensure effective cross-functional coordination and timely closure of action items.
H. Stakeholder and Customer Coordination
· Coordinate with sales, commercial, procurement, quality, and technical teams to meet customer requirements.
· Support resolution of customer complaints relating to product quality, specifications, and delivery.
· Maintain effective working relationships with suppliers, service providers, and other stakeholders.
· Support management in capacity planning, plant expansion, new product introduction, and other strategic initiatives.
I. Supply Chain, Inventory, and Dispatch
· Coordinate with the purchase/procurement department to ensure timely availability of raw materials required for production.
· Coordinate with procurement and stores to ensure availability of consumables, packaging materials, and critical spares.
· Monitor inventory accuracy, material ageing, stock levels, and working capital tied up in inventory.
· Ensure proper storage, identification, handling, and traceability of incoming and finished materials.
· Coordinate with planning, logistics, and sales teams to achieve dispatch schedules and customer delivery commitments.
· Implement material-reconciliation systems and minimise avoidable inventory losses.
· Ensure orderly warehouse operations and compliance with material-handling procedures.
3. Key Performance Indicators (KPIs)
The Plant Head’s performance will be evaluated against agreed KPIs, which will also form the basis for variable pay. Targets and the variable-pay component will be determined after completion of the probation period.
· Achievement of production targets and production plan adherence.
· On-time-in-full (OTIF) delivery and order fulfilment.
· Plant productivity, machine utilisation, OEE, and operational efficiency.
· Product quality, first-pass yield, rejection, rework, and customer complaint levels.
· Manufacturing cost control and reduction in wastage.
· Inventory accuracy, inventory turns, and control of obsolete stock.
· Budget adherence and overall plant financial performance.
· Manpower utilisation and employee productivity.
· Successful introduction of new products and process improvements.
· Machine uptime and maintenance effectiveness, including MTBF, MTTR, and preventive maintenance compliance.
· Safety, statutory compliance, and workplace discipline, including incident/near-miss reporting and closure of safety and audit actions.
· Team development, performance management, and employee engagement.
4. Required Qualifications and Experience
· Graduate in Engineering, Manufacturing, Operations, or a related discipline; a relevant technical qualification will be preferred.
· 10–15 years of proven experience in plant management, production, or manufacturing operations, including at least 5 years as a Plant Head, Factory Manager, Plant Manager, Production Manager, or in an equivalent senior operational role.
· Strong technical knowledge of glass fibre and technical fabrics, including multiaxial glass fibre, glass woven roving, relevant materials, manufacturing processes, and product applications.
· Experience in production planning, quality management, cost control, and people management.
· Sound understanding of budgeting, financial reporting, operational metrics, and performance management.
· Experience in product development, process improvement, and manufacturing optimisation will be preferred.
· Experience implementing Lean Manufacturing, TPM, 5S, Kaizen, OEE improvement, and structured daily management systems will be preferred.
· Sound knowledge of EHS practices, statutory compliance, and factory regulations.
· Exposure to ERP/MRP systems, production dashboards, and data-based performance management will be preferred.
5. Skills and Competencies
Technical and Functional Skills
· Glass fibre and technical fabric product knowledge.
· Manufacturing and production process management.
· Production planning and resource optimisation.
· Quality assurance, inspection systems, and root-cause analysis.
· Maintenance management, TPM, and equipment reliability.
· EHS management and statutory compliance.
· Inventory, supply chain, and dispatch coordination.
· Budgeting, cost control, and financial awareness.
· Reporting, data analysis, and performance monitoring.
· SOP development and business process improvement.
· Lean Manufacturing, Kaizen, and 5S.
· Computer proficiency, including ERP/MRP systems, MS Office, and reporting tools.
Leadership and Behavioural Skills
· Strong leadership and people management.
· Strategic thinking and problem-solving.
· Decision-making and accountability.
· Planning, organising, and execution.
· Effective written and verbal communication.
· Conflict management and stakeholder handling.
· Team motivation and performance orientation.
· Commitment to quality, safety, and continuous improvement.
6. Key Expectations from the Role
The Plant Head is expected to establish a well-structured, accountable, and performance-driven plant environment. The individual must balance production targets, product quality, employee development, safety, inventory control, customer delivery, and financial performance while ensuring that plant operations can support the organisation’s future growth.
