Factory Manager/ Technical Head - Rigid/Plastic Blow Molding Industry

Job Description:-

This position will handle entire plant and all the operation will come under him (Production, Planning & Control/HR & Admin/SCM/maintenance etc.

- Evolved strategies for implementing world-class maintenance processes to curb machine breakdowns, reduce the rejection rate, realize operational efficiencies, control variability, costs as well as reduce the cycle-time; managing a team and guiding staff members to address and resolve performance bottlenecks
- Leadership Experience in Operations & Maintenance of Sodium Sulphate Recovery System
- Should have Experienced in Operations of Viscose, Auxiliary, or Acid H2SO4 Plant.
- Managing Plant with minimum breakdown by Implementing systems like 5S, KAIZEN, FMEA, and WHY-WHY Analysis
- Should have experience of basic conceptualization to Commissioning in VSF Green Field Project, Sodium sulfate Recovery plant.
- Expertise in driving the projects to completion which aim to either minimize loss of material/energy in-process steps or to simplify the process (LEAN approach)
- Exhibited a firm approach to sustain and encourage safe work environments and capabilities to streamline operations; applied continuous improvement principles to increase process & maintenance efficiency and company profits
- Should be Strategic Planner: Developed, initiated, and evaluated new policies, procedures & internal controls; assessed & resolved complex operational problems; resourceful in ensuring sufficient human, financial, and technological resources are available to carry these out

Competencies-

Plant Operations, Operations & Maintenance, Installation & Commissioning, Basic/Detailed Engineering, Quality Management, Operational Excellence, Budgeting & Forecasting, Vendor Management

Key Working Areas:

- Plan &Achieve; sodium sulfate salt production & Its Quality.
- Spearheading entire gamut of operations entailing Production Planning & Process Calculations
- Implementing safety standards through RISK & HAZOP analysis
- Performing design vetting of various equipment with the vendor
- Supervising the selection of equipment based on TBA and meeting with various Foreign and Indian vendors

Highlights:

- Attained cost savings by reduction in raw material, steam & power consumption
- Drove out waste/nonvalue added throughout the Lean Manufacturing
- Implemented ISO 9001-2000, EMS-14000, OHSAS 18001, SA8000 and IMS Systems
- Introduced &implemented; SAP PP Module
- Commissioned equipment such as Multistage Flash Evaporator, Anhydrous Evaporator, Acid Absorption Crystallizer, and Salt Bagging & Packing System

Major Equipment Exposure:

- Multi-stage flash Evaporator, Anhydrous Tripple effect Evaporator, Rotary Vacuum Filters
- Acid Absorption Crystallizer, Steam base Crystallizer, Rotary Drum Dryer
- Steam Ejectors& Vacuum pump, shell & tube heat exchangers, BHE & PHE
- Furnace, Absorbers,



Converter, Reactor, Scrubber.
- Candle Filters, Sand Filters, Filter Press.
- Belt conveyors, Bagging and Packing Systems
- Cooling Towers& Refrigeration System.

Production Planning & Control

- Determine production requirements based on plant capacity and production specifications.
- Plan workflow and schedules for production departments.
- Monitor production status and ensure timely delivery.
- Assist in production risk assessment and mitigation activities.
- Ensure that finished products meet quality standards and customer specifications
- Resolve production issues and escalate unresolved issues to management promptly.
- Monitor and analyze Downtime with Root cause to reduce its impact on Cost, Quality, and Delivery.
- Engaging with internal stakeholders for the smooth operation of the department.

Safety & Environment

- Developing SOPs, JSA, HAZOP & SMP and periodic review for its up-gradation
- Lead/Support/Develop business-specific standards/best practices and efforts as directed by Business and Corporate.
- Assist plants in leading Process Hazards Analysis (PHA) for major risk projects by providing expert PHA methodologies.
- Support PSM Excellence implementation. Identify needs required to comply with PSM requirements.
- Assist the plants in their procedure development and provide direct support to their implementation efforts of new and existing standards and local process safety requirements
- Participate in Process Safety Event investigations/root cause analysis to guide to all plants. In conjunction with site management teams, track corrective actions where business-wide issues are identified.
- Evaluate events and operational results and support the revising / updating of site policies, procedure revisions, and training to address process safety-related findings.

Change management

- Lead Continuous improvement culture among team members to deliver excellence in operations.
- Ensure ABG Operational excellence guidelines are adhered to by continuous training, implemented, and reviewed using the RADAR framework of ABG.
- Knowledge transfer initiatives among inter and intra unit members to continuously improve the processes and systems
- Identify opportunities for joint improvement projects among departments, vendors, and suppliers through CFTs
- taking the lead on transition management, ensuring continuity of operations
- Assist in new product development and enhancements.

Project

- Own the CAPEX projects to improve quality, cost,



productivity within timelines resulting in significant business improvement and customer satisfaction.
- Ensure Onsite and offsite quality inspection of incoming materials to ensure the standards are met for quality parameters
- Ensure completion of process improvement projects within a specified time frame while achieving a cost reduction goal.

Provide management with project status updates, feedback, and appropriate reporting on key responsibilities and objectives.

Regulatory compliance

- Ensure all the relevant regulatory compliances applicable to the operations are adhered to.
- Participate in periodic regulatory compliance audits from external and internal parties to continuously improve systems.

Maintenance

- Coordinate with maintenance teams to ensure maximum equipment availability for operations.
- Ensure implementation of QMS, EMS, OHSMS, and Operational Excellence guidelines for continuous improvement and maintaining standards.
- Coordinate and timely execution and commissioning of new development initiatives for improvements

Planning & budgeting

Propose the department P&B; in the area of Consumption ratios, Maintenance cost, resources management, etc., to management for approvals and achieve the same by deploying resources.

Customer centricity

- Continuously create awareness about customer-centricity among team members to build a customer-oriented mindset.
- Managing customer complaints in consultation with CTS.
- Ensure Quantity & quality parameters of the products/services supplied to internal and external customers
- Provide excellent customer service and ensure customer satisfaction.

People Management

- Ensure employees are aware of their roles and responsibilities and deliverables
- Create an enabling environment to discuss and share people issues at the workplace
- Identify and facilitate appropriate training of competency gaps with the help of the HR department
- Encourage and model the recognition culture at the workplace
- Ensure Safety and Workplace awareness among employees and training wherever required

Develop line managers into people managers to handle day to day grievances with the utmost sensitivity

Regulatory compliance

- Ensure all the relevant regulatory compliances applicable to the operations are adhered to
- Participate in periodic regulatory compliance audits from external and internal parties to continuously improve system

Maintenance

- Coordinate with the maintenance in periodic maintenance and troubleshooting to ensure availability and reliability of equipment.
- Coordinate and timely execution and commissioning of new development initiatives for improvements

Required Experience

Min. 12 years+ of exp. in plastics or rigid packaging industry

Knowledge & skill Blow Moulding/ Extrusion Blow Moulding/ ISB etc. Candidates should be Strong in Administration

Share updated resume at [email protected]

📌 Factory Manager/Technical Head - Rigid/Plastic Blow Moulding Industry (Hyderabad)
🏢 People Alliance Workforce
📍 Hyderabad