Plant Head - Large Plant

JOB PURPOSE

• Lead production planning and execution for the assigned plant;
• Ensure and provide inputs for improvement project planning and execution, raise the capex requirements;
• Review metrics to ensure achievement of set production objectives;

Coordinate with other departments such as maintenance, quality, improvement, etc. to align and remove roadblocks

PRINCIPAL ACCOUNTABILITIES

1. Production Planning

▪ Understand the targets set for sales, variable cost, fixed cost, etc. set for Business Development

Propose PPM targets, PQCD cost, etc. at the beginning of year to ensure EBITDA objectives are met

▪ Develop plans to ensure minimum production cost in line with the business plan to achieve the PQCD targets by ensuring continuous improvement.

▪ Conduct discussions with the key customer – Purchase and PPC to finalize the man and material planning for the coming month, identify and provide suggestions for resolution of issues.

▪ Execute the production plan as per the PPC guidelines to meet the Customer schedule.

2. Improvement Projects

▪ Define projects in line with the overall improvement targets for production, maintenance, etc.

Analyze and identify lines with opportunities to improve / reduce cycle time, etc. Provide ideas and brainstorm with the improvement of the ME team on opportunities and scope for improvements in manufacturing processes through process elimination, process merging, changes in layout etc.

▪ Raise monthly capex requirements for projects, share input on manpower savings with HR and other factors impacting P&L (fixed / variable cost) for review by Plant Head.

▪ Monitoring Kaizen, 5s & TPM training & train employees for multi-machining & multi skilling.

3. IHR & Customer Complaints

▪ Monitor & Reduce IHR level by analyzing the product and process defects and taking corrective action by improving production process and deploying the same horizontally.

▪ Review day-to-day production process for rejection monitoring (process wise & product wise) to identify top defect for down the line Implementation of corrective and preventive actions.

▪ Monitoring SPC (Statistical Process Chart) & PQC (Process Quality Chart) reports to correct production process.

4. Safety

▪ Monitoring implementation of EHS guidelines, implementing various EHS systems, monitoring strict usage of PPE’s.

▪ Monitoring, implementation & adherence to health and safety procedures & documenting near miss, may happen & unsafe condition to take necessary actions to prevent accidents.

▪ Keeping the records of near miss accidents & implement near miss kaizens to ensure zero accident & build safety culture.

▪ Monitoring for audit compliance & taking corrective actions to clear nonconformities.

5. Internal Audit and Documentation

▪ Monitor internal audit for auditing adherence to Safety, TPM,5s at the shop floor.

▪ Ensure completeness of documents for IATF, Customer & other external audits

▪ Workout and implement SOP’s (Standard operating procedures), OPL (One Point lesson) for production process.

▪ Monitoring Employees Skill matrix & Preparing Production MIS.

▪ Document preparation for IATF, OSHAS, Customer & other external audits.

6. Review and execution

▪ Coordinate and seek alignment across functions / departments such as maintenance, purchase, store, HR, etc. to achieve the set targets

▪ Anticipate and resolve escalated issues, remove roadblocks synergies and ensure overall targets are achieved

▪ Analyze, consolidate and put up manpower requirements to the HR department

▪ Closely monitor early failure report (IFR), inhouse rejection cost (IHR), scrap cost to achieve set targets

7. Team development

▪ 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 time

QUALIFICATION

▪ Minimum Qualification required : BE / B.Tech (Full-time)

▪ MBA / PG in Operations / SCM will be an added advantage

WORK EXPERIENCE

▪ Minimum 18-20 years of experience

▪ In-depth knowledge of Automotive Transmission / Gears products and its manufacturing processes (MANDATORY)

▪ Basic financial and administrative knowledge

▪ Experience of production management of similar products categories (Automotive Transmission Components)

▪ Exposure to managing 2W / 4W OEM Customers (Preferred)