Role & responsibilities

Key Responsibilities

1. Production Planning & Execution

* Prepare daily, weekly and monthly production plans based on committed delivery schedules.
- Plan and coordinate activities across winding, core, assembly, tanking, ovening, oil filtration, testing and dispatch.
- Monitor production against targets and identify bottlenecks affecting delivery.
- Ensure availability and proper allocation of manpower, machines, materials and other resources.
- Coordinate with Purchase, Stores, Design and Quality teams to prevent production delays.
- Improve productivity and reduce manufacturing cycle time and rework.

1. Quality & Process Control

* Lead and guide the Quality team for incoming, in-process and final inspection.
- Ensure adherence to approved drawings, GTPs, manufacturing procedures and applicable IS/IEC/customer specifications.
- Establish appropriate stage-wise quality checks and hold points.
- Ensure proper documentation and traceability of critical manufacturing activities.
- Drive reduction in rejection, rework and recurring quality issues.

1. Root Cause Analysis & Troubleshooting

A major requirement of this position is the ability to technically investigate manufacturing and testing failures. The Plant Head should be able to:
- Investigate in-process failures and abnormalities.
- Perform structured Root Cause Analysis (RCA).
- Identify whether the problem originates from design, material, workmanship, process or testing.
- Define and implement Corrective and Preventive Actions (CAPA).
- Guide the team in troubleshooting issues such as:
- Low IR/Megger values
- Ratio/tap-position abnormalities
- High resistance or unbalance
- Excessive losses
- Impedance deviations
- HV/LV withstand failures
- Induced/DVDF test failures
- Oil leakage
- Temperature-rise related issues




- Other routine and type-test abnormalities
- Maintain records of major failures and ensure learning is incorporated into future manufacturing.

1. Testing & Customer Inspections

* Ensure transformers are completely ready before customer/third-party inspection.
- Review internal test results before offering transformers for inspection.
- Coordinate and handle inspections by customers, utilities and third-party agencies.
- Technically represent the company during inspections and resolve observations raised by inspectors.
- Ensure testing is carried out according to applicable IS/IEC standards and approved specifications.
- Ensure inspection observations and NCRs are closed within defined timelines.

1. Team Leadership

* Lead Production, Quality and Testing teams and establish explicit accountability.
- Conduct regular production and quality review meetings.
- Guide engineers and supervisors in solving day-to-day technical and operational problems.
- Develop technical capability of junior engineers through practical training and mentoring.
- Maintain discipline, safety and coordination across departments.
- Evaluate manpower requirements and support recruitment and development of the plant team.

1. After-Sales & Site Support

* Technically guide the after-sales/service team for transformer-related complaints.
- Analyse customer complaints and determine probable root causes before deputing teams to site.




- Guide site teams regarding required checks, instruments and corrective actions.
- Review site failure reports and determine whether issues relate to manufacturing, installation, protection, loading or site conditions.
- Ensure customer complaints are closed quickly while protecting the companys technical and commercial interests.
- Feed learnings from site failures back into Production, Design and Quality.

1. Dispatch & Delivery Responsibility

* Ensure transformers are technically and commercially ready for dispatch as per committed schedules.
- Review pending jobs and proactively escalate risks to delivery.
- Coordinate inspection clearance, testing documentation, accessories, packing and dispatch readiness.
- Ensure transformers are dispatched without pending technical or quality issues.

1. Continuous Improvement

* Identify bottlenecks and opportunities for improvement across manufacturing processes.
- Implement systems for reducing rejection, rework, testing failures and production delays.
- Develop SOPs, checklists and process controls for critical activities.
- Track recurring problems and ensure permanent corrective action rather than temporary solutions.
- Promote 5S, workplace safety and preventive maintenance practices.

Key Performance Indicators (KPIs)

Performance of the Plant Head will primarily be measured on:
- On-time production and dispatch
- Production plan vs. actual achievement
- First-pass testing success rate
- In-process rejection and rework
- Customer inspection clearance / first-time acceptance
- Reduction in recurring quality failures
- Customer/site complaint closure time
- Manufacturing cycle time
- Productivity and manpower utilisation
- Compliance with quality and safety systems

📌 Plant Head Transformer Manufacturing (Bhopal)
🏢 Western Electrical Unit No 2
📍 Bhopal