Role Deliverables

Key Deliverables

Theme of the Role

The Plant Head will lead end-to-end manufacturing operations of fan products with a strong focus on fractional horsepower (FHP) motor production, including stator/rotor manufacturing, winding, assembly, testing, and final product integration. The role demands operational excellence, deep technical understanding of low-power electric motors, and strong leadership to drive productivity, quality, and cost efficiency.

Key Deliverables

. End-to-End Plant Operations

- Oversee complete manufacturing operations: motor production (FHP), fan assembly, testing, and dispatch
- Ensure production targets are met across multiple product lines (ceiling, table, pedestal, exhaust fans)
- Drive plant efficiency, capacity utilization, and throughput improvement

2. FHP Motor Manufacturing Oversight

- Manage processes including:
- Stator lamination stacking and insulation
- Copper winding (manual/automatic winding machines)
- Rotor casting (die-casting for squirrel cage rotors) and balancing
- Motor assembly and performance testing

- Ensure motor efficiency, reliability, and compliance with standards (e.g., IS/IEC)
- Optimize motor design-to-manufacturing alignment for performance and cost

3. Production Planning & Control

- Develop production schedules aligned with demand forecasts
- Monitor line balancing and bottlenecks in motor and fan assembly lines
- Improve Overall Equipment Effectiveness (OEE)

4. Quality Management

- Implement robust quality systems for both motors and finished fans
- Reduce rejection rates (winding defects, vibration issues, noise, overheating, etc.)
- Lead root cause analysis and corrective/preventive actions (CAPA)

5. Maintenance & Engineering

- Ensure preventive and predictive maintenance of winding machines, die-casting machines, testing rigs, and assembly lines
- Drive automation in winding, testing, and assembly processes
- Lead new product industrialization (NPI)



for energy-efficient fans (e.g., BLDC transition if applicable)

6. Cost Optimization

- Control key cost drivers: copper, aluminum, electrical steel, labor, and energy
- Improve material yield and reduce scrap in winding and casting processes
- Drive value engineering initiatives

7. Supply Chain Coordination

- Work closely with procurement for sourcing of critical components (laminations, copper wire, bearings, capacitors)
- Optimize inventory and ensure uninterrupted production

8. Team Leadership

- Lead cross-functional teams: production, maintenance, QA, supply chain, and HR
- Develop technical capabilities of teams in motor manufacturing processes
- Build a performance-driven culture

9. Safety & Compliance

- Ensure compliance with statutory, environmental, and electrical safety standards
- Promote safe handling of materials like varnishes, resins, and molten metals (in rotor casting)

10. Continuous Improvement

- Implement Lean Manufacturing, TPM, Six Sigma initiatives
- Drive productivity improvement and waste reduction
- Encourage innovation in motor efficiency and manufacturing processes

Competencies -Must have’

- Motor efficiency & performance compliance
- Production output vs plan
- OEE (Overall Equipment Effectiveness)
- First Pass Yield (FPY) in motor manufacturing
- Rejection / rework rates (winding, balancing, noise)
- Cost per unit (motor + fan)
- On-time delivery (OTD)
- Safety incidents

Competencies “Wants”

- Deep knowledge of:
- Fractional horsepower motors (single-phase induction motors, capacitor-run motors)
- Motor winding techniques and insulation systems
- Rotor die-casting and dynamic balancing
- Fan performance parameters (air delivery, noise, efficiency)
- Familiarity with IS/IEC standards for motors and fans

Critical personality attributes

- Robust leadership and decision-making ability
- Problem-solving and analytical mindset
- High accountability and ownership
- Effective communication and stakeholder management

📌 Plant Head at Vasai-Thane ( Electronic Manufacturing Unit)
🏢 Rexnord Electronicsntrols
📍 Thane