Company: Sheetal Metals

Industry: Aluminium Pressure Die Casting & Precision Machining

Location: Dewas, Madhya Pradesh

Department: Plant Operations

Position: Plant Head

Employment Type: Full-Time

Reporting To: Management

About Sheetal Metals

Sheetal Metals is engaged in manufacturing aluminium pressure die-cast components with complete in-house facilities for pressure die casting, VMC/CNC machining, fettling, buffing, shot blasting, drilling, powder coating, inspection and packing.

Position Objective

We are looking for an experienced and result-oriented Plant Head who will be responsible for the complete operation of the manufacturing plant. The candidate must ensure achievement of production, quality, delivery, cost, safety and profitability targets while maintaining strong systems and workforce discipline.

Key Responsibilities

1. Production and Plant Operations

* Manage complete plant operations, including pressure die casting, fettling, shot blasting, VMC/CNC machining, drilling, powder coating, quality inspection and packing.

* Prepare and execute daily, weekly and monthly production plans as per customer requirements.

* Ensure maximum utilization of 180T, 350T and 650T pressure die-casting machines and other plant equipment.

* Monitor daily production, cycle time, rejection, rework, downtime and dispatch performance.

* Identify production bottlenecks and implement corrective actions.

* Ensure timely completion of current die trials, sample development and mass-production approval.

* Coordinate with Purchase, Stores, Quality, Maintenance, Tool Room, Planning and Dispatch departments.

2. Quality Management

* Ensure compliance with customer specifications, drawings, control plans, SOPs and inspection standards.

* Lead implementation and maintenance of IATF 16949 and ISO quality-management systems.

* Ensure proper implementation of APQP, PPAP, PFMEA, Control Plan, MSA, SPC and 8D.

* Reduce internal rejection, customer rejection, rework and warranty complaints.

* Lead root-cause analysis and corrective/preventive actions for quality problems.

* Ensure traceability of raw material, production batches, process parameters and finished goods.

* Prepare the plant for customer, system, process and product audits.

* Ensure that customer complaints are closed within the committed timeline.

3. Pressure Die-Casting Process Control

* Ensure control of die temperature, metal temperature, injection parameters, holding pressure, cooling time and cycle time.

* Monitor aluminium melting, alloy composition, degassing, dross generation and metal recovery.

* Improve casting yield and reduce porosity, blowholes, cold shuts, misruns, shrinkage, leakage and ejection-related rejection.

* Ensure preventive maintenance of dies, furnaces, PDC machines, compressors, cooling systems and utilities.

* Coordinate die correction, repair, modification and preventive maintenance.

* Ensure process parameters are standardized, recorded and followed by operators.

4. Productivity and Cost Control

* Improve OEE, productivity,



machine utilization and manpower efficiency.

* Control the consumption of aluminium, powder, LPG/fuel, electricity, tools, inserts, consumables and packing material.

* Monitor power cost per kilogram, conversion cost per component and overall manufacturing cost.

* Reduce scrap, rejection, rework, breakdown and idle manpower.

* Develop and implement cost-saving and process-improvement projects.

* Review actual manufacturing costs against product quotations and budgeted costs.

* Ensure effective utilization of the plant’s rooftop solar-power system and other utilities.

5. Maintenance and Tool Management

* Ensure implementation of preventive, predictive and breakdown-maintenance systems.

* Monitor machine-wise maintenance schedules and breakdown history.

* Ensure minimum machine downtime and availability of critical spares.

* Monitor VMC/CNC tool life, tool consumption, tool breakage and cost per component.

* Ensure proper maintenance of dies, fixtures, gauges and inspection instruments.

* Coordinate with external vendors for machine, die, fixture and utility repairs.

6. Planning, Inventory and Dispatch

* Review customer orders, available capacity, raw materials, WIP and finished-goods inventory.

* Ensure production priorities are aligned with committed dispatch dates.

* Control excessive WIP and maintain optimum inventory levels.

* Ensure availability of aluminium, consumables, tools, inserts and packaging material.

* Monitor daily dispatch plans and ensure on-time delivery.

* Prevent production delays caused by poor material planning or interdepartmental coordination.

7. Team Management and Discipline

* Lead Production, Quality, Maintenance, Tool Room, Stores and Dispatch teams.

* Allocate responsibilities and establish measurable KRAs and KPIs for departmental heads.

* Conduct daily morning production-review meetings.

* Develop supervisors, engineers and operators through regular training.

* Maintain employee discipline, attendance, safety and accountability.

* Prepare and maintain operator skill matrices and training plans.

* Create a culture of ownership, problem-solving and continuous improvement.

* Ensure appropriate manpower planning across all shifts.

8. Safety and Statutory Compliance

* Ensure safe operation of PDC machines, furnaces, compressors, grinders, VMC/CNC machines and powder-coating facilities.

* Enforce the use of PPE and compliance with safety procedures.

* Conduct periodic safety audits, risk assessments and emergency drills.

* Ensure compliance with Factory Act, pollution-control, fire-safety and other statutory requirements.





* Investigate accidents and near-miss incidents and implement preventive actions.

* Maintain proper housekeeping through 5S practices.

Key Performance Indicators

The Plant Head’s performance will be evaluated based on:

* Production target achievement

* On-time delivery

* Overall Equipment Effectiveness

* Machine utilization and downtime

* Casting yield and aluminium recovery

* Internal rejection and rework percentage

* Customer rejection and complaint closure

* Power and fuel cost per kilogram

* Tool and consumable cost per component

* Manpower productivity

* Inventory and WIP control

* Preventive-maintenance compliance

* Audit performance

* Safety performance

* Cost-saving achievements

* Plant profitability

Required Qualification

* B.E./B.Tech or Diploma in Mechanical, Production, Automobile or Metallurgical Engineering.

* Additional qualification in Operations Management or Quality Management will be preferred.

Required Experience

* Minimum 12–18 years of manufacturing experience.

* Minimum 5 years of experience in a senior Plant Head, Operations Head or Production Head position.

* Strong experience in aluminium pressure die casting is mandatory.

* Experience in automotive, lighting, electrical, pump, motor or engineering-component manufacturing will be preferred.

* Practical exposure to PDC machines between approximately 180T and 650T will be advantageous.

* Experience in machining, powder coating and complete component manufacturing is desirable.

Technical Skills Required

* Aluminium pressure die-casting process

* ADC12 and similar aluminium alloys

* PDC machine and furnace operations

* VMC and CNC machining

* Die maintenance and die trials

* Casting-defect analysis

* APQP, PPAP, PFMEA and Control Plan

* IATF 16949 and ISO systems

* 7 QC tools, 8D, SPC and MSA

* OEE, TPM, 5S, Kaizen and Lean Manufacturing

* Production planning and capacity calculation

* Costing and consumption control

* ERP/MIS and Microsoft Excel

* Customer and supplier audits

Preferred Candidate Profile

* Strong hands-on plant-management experience

* Technically sound in pressure die casting and machining

* Capable of taking complete responsibility for plant performance

* Strong analytical and problem-solving ability

* Disciplined and process-oriented

* Effective team leader with good communication skills

* Commercially aware and capable of controlling manufacturing costs

* Comfortable working directly with customers, auditors and senior management

* Willing to relocate to or work in Dewas, Madhya Pradesh

Application Requirements

Interested candidates should share their updated CV along with the following information:

* Current designation

* Current company and location

* Total experience

* Pressure die-casting experience

* Current CTC

* Expected CTC

* Notice period

* Reason for job change

* Current team size

* Major cost-saving or productivity achievements

Pay: ₹90,000.00 - ₹100,000.00 per month

Benefits:

- Flexible schedule
- Paid sick time
- Provident Fund

Work Location: In person

📌 Plant Head (Dewas)
🏢 SHEETAL METALS
📍 Dewas