Job Description: General Manager Technical (AAC Blocks Manufacturing)

Position Details:

Job Title - General Manager Technical

Department - Manufacturing / Plant Operations

Reports To Managing Director / Chief Operating Officer

Reportees - Plant Manager, Production Manager, Quality Control Head, Maintenance Manager, Utilities/Boiler In-charge

Industry - Building Materials AAC (Autoclaved Aerated Concrete) Blocks Manufacturing

Experience Required - 18-25 years, with minimum 5 years in a senior leadership role in AAC/building materials manufacturing

Qualification - B.Tech/B.E. in Mechanical, Civil, Chemical, or Ceramic Engineering (M.Tech/MBA preferred)

Job Purpose

To lead and be fully accountable for the technical and operational performance of the AAC blocks manufacturing plant covering production, quality, maintenance, process optimization, and plant safety — while driving cost efficiency, capacity utilization, and product consistency in line with business targets.

Key Responsibilities

1. Production & Plant Operations

- Own end-to-end plant operations: raw material handling, mixing/dosing, mould filling, autoclaving, cutting, and curing processes.
- Drive production planning to meet volume, quality, and dispatch targets with minimal downtime.
- Monitor and optimize key process parameters — slurry density, mould rise time, green cake cutting, autoclave pressure/temperature cycles — to ensure consistent block quality (density, compressive strength, dimensional accuracy).
- Ensure optimal utilization of installed capacity and continuously work to improve OEE (Overall Equipment Effectiveness).

2. Technical & Process Expertise

- Provide hands-on technical leadership on AAC process chemistry — fly ash/sand slurry, lime, cement, gypsum, aluminum powder dosing, and reaction control.
- Troubleshoot process deviations (under/over-rising, cracking, autoclave defects, density variation) and implement corrective actions.




- Lead process improvement and cost-reduction projects (raw material substitution, energy efficiency, cycle time reduction, steam/autoclave optimization).
- Evaluate and implement new technology, automation, and equipment upgrades in line with industry best practices.

3. Quality Assurance

- Establish and enforce QA/QC systems to ensure blocks meet IS 2185 (Part 3) and other applicable standards.
- Drive root-cause analysis and CAPA (Corrective and Preventive Action) for quality complaints and rejections.
- Maintain and improve testing protocols for raw materials, in-process checks, and finished products.

4. Maintenance & Reliability

- Oversee preventive, predictive, and breakdown maintenance of critical equipment — batching plant, autoclaves, boilers, cutting machines, curing systems, material handling, and utilities.
- Minimize unplanned downtime through robust maintenance planning and spares management.
- Ensure protected and compliant operation of pressure vessels (autoclaves) and boilers.

5. Team Leadership

- Lead, mentor, and build a strong technical/operations team across production, quality, and maintenance functions.
- Drive a culture of accountability, continuous improvement (Kaizen/Lean), and skill development through training programs.
- Manage manpower planning, shift operations, and performance management for the plant technical team.

6. Safety, Health & Environment (SHE)

- Ensure strict compliance with EHS standards, particularly around autoclave/pressure vessel safety, material handling, and dust control.
- Drive a zero-incident culture through safety audits, training, and adherence to statutory requirements (Factories Act,



Boiler regulations, Pollution Control norms).

7. Cost & Business Performance

- Own and control the plant's operating budget — manpower, raw material consumption, power/fuel, and maintenance costs.
- Drive initiatives to reduce cost per cubic meter of AAC blocks produced.
- Report plant performance (production, quality, cost, downtime) to leadership through structured MIS/dashboards.
- Coordinate with Procurement (raw material quality/availability), Sales (dispatch planning), and R&D; (new product development) functions.

Required Technical Skills & Knowledge

- Strong hands-on understanding of the AAC block manufacturing process — slurry preparation, autoclaving, curing cycles, and reaction chemistry.
- Working knowledge of fly ash/sand-based building material manufacturing processes and raw material characteristics.
- Familiarity with pressure vessel/autoclave operations, boiler operations, and relevant statutory/safety compliance.
- Experience with plant automation/PLC-based control systems used in AAC or similar process plants.
- Sound knowledge of IS codes/standards applicable to AAC blocks and building materials.
- Strong analytical skills for process troubleshooting, yield improvement, and cost optimization.
- Exposure to Lean Manufacturing / TPM / Six Sigma practices is an added advantage.

Desired Candidate Profile

- Prior experience as GM/Plant Head/Technical Head in an AAC blocks plant, or in a closely related building materials industry (cement, fly ash bricks, concrete products, sand-lime bricks, precast concrete).
- Proven track record of running a plant profitably — meeting production targets, quality benchmarks, and cost budgets.
- Strong people management skills with experience leading cross-functional plant teams of 50+ personnel.
- Willingness to be based at the plant location and available for extended/flexible hours during critical operations.

📌 General Manager - Technical (Tamil Nadu)
🏢 Renaatus Procon
📍 Tamil Nadu