Plant Head Automotive Casting Manufacturing

Position Summary

The Plant Head will be responsible for the overall leadership and management of the manufacturing plant producing automotive casting components. The role is accountable for Production, Quality, Maintenance, Engineering, Supply Chain, Cost, Safety, Delivery, Customer Satisfaction, and overall plant profitability while driving operational excellence through Lean Manufacturing, TPM, Six Sigma, and continuous improvement initiatives.

Key Responsibilities

Plant Operations

- Lead end-to-end manufacturing operations including Foundry/Casting, Machining, Assembly, Finishing, Tool Room, Maintenance, Quality, Stores and Dispatch.
- Ensure achievement of production, quality, cost, delivery and safety (PQCDSM) targets.
- Drive plant productivity, capacity utilization and operational efficiency.
- Monitor plant KPIs including OEE, Yield, Rejection, Scrap, Machine Utilization and On-Time Delivery.
- Develop annual operating plans and monitor plant performance against business objectives.

Production & Manufacturing Excellence

- Oversee casting operations including melting, die/sand/gravity casting, heat treatment, machining and finishing.
- Optimize manufacturing processes to improve productivity and reduce manufacturing costs.
- Implement Lean Manufacturing, TPM, Kaizen, 5S, Six Sigma and Industry 4.0 initiatives.
- Lead automation and digital manufacturing projects to improve operational efficiency.
- Drive reduction in cycle time, rejection, rework and downtime.

Quality & Customer Management

- Ensure compliance with IATF 16949, ISO 9001, ISO 14001 and customer-specific requirements.
- Lead customer audits, process audits and certification audits.
- Drive Zero Defect initiatives through CAPA, PFMEA, SPC, APQP and PPAP.
- Address customer complaints through structured problem-solving methodologies (8D, Why-Why Analysis, Fishbone, etc.).




- Ensure achievement of customer quality and delivery metrics.

Maintenance & Engineering

- Ensure preventive and predictive maintenance of plant equipment.
- Improve equipment reliability and machine availability.
- Lead current equipment installation, commissioning and capacity expansion projects.
- Optimize utilities and energy consumption.

Supply Chain & Inventory

- Coordinate with Procurement, Planning and Logistics for uninterrupted production.
- Optimize inventory, material flow and warehouse operations.
- Ensure timely dispatch and customer delivery performance.

Cost & Financial Management

- Own plant budget, manufacturing cost and profitability.
- Drive cost reduction through process improvements, productivity enhancement and waste elimination.
- Monitor CapEx and OpEx budgets.
- Prepare monthly MIS, operational dashboards and management reports.

Leadership & People Management

- Lead and develop cross-functional teams across Production, Quality, Maintenance, Engineering, SCM and HR.
- Build a high-performance culture focused on accountability and continuous improvement.
- Develop succession planning and capability-building initiatives.
- Foster employee engagement and maintain harmonious industrial relations.

Health, Safety & Compliance

- Ensure compliance with statutory, environmental and safety regulations.
- Promote a Zero Accident culture through EHS initiatives.
- Ensure adherence to all legal and regulatory requirements applicable to manufacturing operations.

Desired Candidate Profile

Education

- B.E./B.Tech/Diploma in Mechanical, Production, Metallurgy or Industrial Engineering.

Experience

- 15 to 20 years of experience in automotive manufacturing with significant exposure to casting/foundry operations.
- Minimum 5+ years in a Plant Head/Operations Head/Manufacturing Head leadership role.
- Experience in Tier-1/Tier-2 automotive component manufacturing preferred.

📌 Plant Head (Sambhajinagar)
🏢 Amor Management Consultants
📍 Sambhajinagar