Job Title

Plant Head

Department

Operations / Manufacturing

Reports To

Managing Director / Director Operations

Location

Manufacturing Plant

Job Summary The Plant Head is responsible for the overall management and performance of the fastener manufacturing plant. The role ensures safe, efficient, and profitable operations by leading production, quality, maintenance, supply chain, engineering, and support functions. The Plant Head is accountable for achieving business objectives related to production, quality, cost, delivery, productivity, customer satisfaction, and continuous improvement.

Key Responsibilities

Plant Operations

- Lead end-to-end manufacturing operations, including wire drawing, cold forging, thread rolling, trimming, heat treatment, surface finishing, sorting, packing, and dispatch.
- Develop and execute production plans to meet customer demand and delivery schedules.
- Optimize plant capacity, machine utilization, and workforce productivity.
- Ensure smooth coordination among Production, Quality, Maintenance, Planning, Stores, Purchase, and Dispatch teams.

Production Management
- Achieve daily, weekly, and monthly production targets.
- Improve Overall Equipment Effectiveness (OEE), throughput, and cycle times.
- Minimize production losses, bottlenecks, and downtime.
- Monitor and improve manufacturing efficiency and labor productivity.

Quality Management
- Ensure products comply with customer specifications and applicable standards such as DIN, ISO, ASTM, BS, and JIS.
- Reduce rejection, rework, and customer complaints through robust quality systems.
- Oversee inspection and testing, including dimensional inspection, tensile testing, hardness testing, torque testing, coating thickness, and salt spray testing.
- Lead corrective and preventive actions (CAPA) for quality issues.

Maintenance & Engineering
- Establish preventive and predictive maintenance programs for all production equipment.




- Improve equipment reliability and reduce breakdowns.
- Ensure timely availability of spare parts, tooling, and utilities.
- Support installation and commissioning of new equipment and process improvements.

Supply Chain & Inventory
- Coordinate with Procurement and Planning to ensure uninterrupted availability of raw materials and consumables.
- Maintain optimum inventory levels for raw materials, work-in-progress, and finished goods.
- Ensure timely dispatch of finished products to customers.

Cost Management
- Prepare and manage the plant operating budget.
- Monitor manufacturing costs and identify cost-reduction opportunities.
- Improve material yield and reduce scrap, tool consumption, energy usage, and maintenance costs.
- Drive initiatives to improve plant profitability and operational efficiency.

Safety, Environment & Compliance
- Ensure compliance with statutory, environmental, and occupational health and safety regulations.
- Promote a robust safety culture across the plant.
- Conduct regular safety audits, risk assessments, and employee training.
- Ensure safe handling of chemicals, furnaces, and plating operations.

Continuous Improvement
- Drive Lean Manufacturing, TPM, 5S, Kaizen, and Six Sigma initiatives.
- Lead cross-functional improvement projects focused on productivity, quality, cost, and delivery.
- Foster a culture of operational excellence and continuous learning.

Leadership & People Development
- Lead and develop production, quality, maintenance, planning, engineering, and support teams.




- Set performance goals and conduct regular performance reviews.
- Identify training needs and develop employee capabilities.
- Build a high-performance culture focused on accountability, teamwork, and continuous improvement.

Key Performance Indicators (KPIs)
- Production target achievement
- Overall Equipment Effectiveness (OEE)
- Capacity utilization
- On-Time Delivery (OTD)
- Rejection and scrap percentage
- Customer complaint rate (PPM)
- Machine uptime and breakdown frequency
- Conversion cost per kilogram
- Inventory turnover
- Energy consumption per tonne
- Lost Time Injury (LTI) frequency
- EBITDA and manufacturing cost reduction

Qualifications
- Bachelor's degree in Mechanical, Production, Industrial, Metallurgical, or Manufacturing Engineering.
- MBA in Operations or Manufacturing Management is preferred.

Experience
- 15–20 years of manufacturing experience, with at least 5–8 years in a senior leadership role.
- Proven experience in fastener manufacturing, including cold forging, thread rolling, heat treatment, and surface finishing.
- Experience managing large manufacturing teams and driving operational excellence.

Technical Competencies
- Fastener manufacturing processes
- Cold forging and thread rolling technology
- Heat treatment and surface coating processes
- Tooling and die management
- Lean Manufacturing, TPM, Six Sigma, and 5S
- Production planning and inventory management
- Cost control and budgeting
- Quality management systems and customer standards
- ERP systems (SAP, Oracle, Microsoft Dynamics, etc.)
- Root Cause Analysis (RCA), CAPA, FMEA, and Statistical Process Control (SPC)

Leadership Competencies
- Strategic thinking
- Operational excellence
- Decision-making
- Team leadership and coaching
- Change management
- Customer focus
- Problem-solving and analytical skills
- Effective communication and stakeholder management
- Financial and business acumen

📌 Plant Head (Indore)
🏢 KANAL ENTERPRISES
📍 Indore