Plant Head - Small Plant

JOB PURPOSEPlan, organize and control plant operations for the assigned plant to deliver on the production, quality cost and delivery (PQCD) targets and ensure safety and morale of the team; Drive improvement projects and cost saving initiatives; Monitor budget and target achievement; Review metrics to ensure achievement of set production objectives for PBT, Quality, NPD, inventory turnover, customer PPM, MPC, etc.PRINCIPAL ACCOUNTABILITIESProduction Planning & Budgeting- Lead the budgeting exercise for the plant based on sales plan shared by BD including aspects of fixed/ variable parts planning, expenses, EBIDTA etc.; Ensure alignment of fixed and variable costs with larger management direction; Adjust budget planning through the year based on volume changes - Lead monthly, weekly and shift planning for plant production and achieve alignment with targets set for sales, variable cost, fixed cost, etc.; Oversee and align sales planning, capacity planning and manpower allocation - For production planning, based on customer indents direct PPC and MP&L including manpower, scheduling, resources, etc. - Lead daily production morning meetings with all plant department heads to track the actual vs. daily target achievement; Interpret and provide course correction inputs on the variance / non achievementReview & Operations Management- Review daily operations through key parameters such as OEE, Fixed cost, variable cost and losses impacting the PnL; Monitor issues causing losses such as inefficiencies, material non-availability, manpower, etc. Ensure efficiency, profitability and cost stability; Identify and expedite areas of improvement - On a daily basis, determine dispatch quantities and review reports for commodity failed to dispatch based on overall monthly target bifurcated by product categories and quantities - Prepare plans and anticipate manpower requirements to ensure adequacy of manpower for production; Ensure compliance and compatibility with union; Lead execution of contracts such as labour, housekeeping, wage settlement, etc. finalized by corporate HR, BU HR, ER, etc. - Step in to resolve issues and concerns related to manpower, material, capacity constraints, material mix, etc. - In case of manpower crunches, work with agencies to ensure adequate manpower supply - Ensure all statutory compliances are met for the plant across quality, safety, HR, etc.Improvement Projects- Define and lead projects to control costs and improve efficiency such as value engineering, reduction of non-value added activities, energy saving, tool line enhancement, etc. - Direct project planning and execution for continuous improvement projects, review and add to projects on monthly basis and validate cost savings with support of BU FinanceMaterial and Supply Chain management- Engage with suppliers to understand issues causing quality / capacity issues and inability to meet commitments - Use market survey, inputs from customers/ suppliers and own network to identify alternate suppliers where suppliers’ issues persist; Undertake audit and submit report to seek quality approval and corporate approval (cost, SOB, etc.)NPD and Manufacturing Engineering- Ensure smooth and timely new product launches, drive and resolve issues to manage delays / setbacks - Direct team for improvement in manufacturing engineering, such as improvements in cycle time, clubbing of stage and layoutsCustomer management & Quality management- Engage with customers regarding sales volumes, SOPs, PPM, customer audits, new product launches, etc.; Understand and interpret customer specific grievances and open points to meet and satisfy them adequately - Drive in-depth analysis of quality measures and standards to determine appropriate preventive actions; Review faulty tree analysis, fish bone analysis, simulations, etc. to determine action steps; Guide team and make recommendations related to automations, improved resource planning, anticipation of supplier issues, quality check issues, etc.Team development- Participate in recruitment process to identify the right talent across positions within the team - 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 timeQUALIFICATIONMinimum QualificationBachelor’s degree in Chemical Engineering / Chem Technology – Paint Technology (B.Tech Chemical Tech-Paints preferred)WORK EXPERIENCE- Minimum 15-20 years of experience - In-depth knowledge of advance Paint Technology and automotive painting processes - Experience of production management of Two- Wheeler Paint Shop is preferred - Knowledge of robotic painting process for ABS & Sheet metal components is a must - Knowledge of P & L concepts of Paint Shop will be added advantage.

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