JOB DESCRIPTIONPlant Manager – EPE Manufacturing Plant

Location: Akrale MIDC, Dindori, Nashik, Maharashtra
Department: Plant Operations / Manufacturing
Position: Plant Manager
Reporting To: Management / Partners
Industry: EPE Foam / Plastic Processing / Packaging & Industrial Products

1. Job Purpose

The Plant Manager will be responsible for the overall operation and performance of the EPE manufacturing plant, ensuring safe, efficient and cost-effective production while maintaining product quality, delivery commitments and disciplined plant operations.

The person will lead the production, maintenance, quality, manpower and day-to-day plant activities and will be responsible for achieving production targets with optimum utilization of machines, manpower, raw materials, LPG, electricity and other resources.

2. Key ResponsibilitiesA. Production Management

- Plan and execute daily, weekly and monthly EPE production as per customer and dispatch requirements.
- Ensure achievement of production targets in terms of quantity, density, thickness, width, quality and productivity.
- Monitor EPE extrusion line parameters and ensure stable production.
- Optimize machine settings to minimize start-up losses, process scrap, rejection and downtime.
- Monitor and control:
- Melt temperature
- Melt pressure
- Gas/LPG parameters
- Cooling conditions
- Take-off speed
- Line speed
- Product density
- Thickness and width
- Winding and cutting parameters
- Ensure proper changeover procedures between different products, densities and thicknesses.
- Identify production bottlenecks and implement corrective actions.
- Maintain production records and prepare daily/monthly production reports.

B. Raw Material & Process Control

- Ensure proper planning and availability of LDPE, masterbatch, additives and other production materials.
- Monitor raw-material consumption against standard norms.
- Control LPG consumption and identify opportunities for process optimization.
- Maintain appropriate batch-wise traceability of raw materials and finished products.
- Work closely with the purchase/store team to avoid production interruptions due to material shortages.
- Monitor material wastage and develop initiatives to reduce consumption.

C. Quality Management

- Ensure EPE products meet defined specifications and customer requirements.
- Maintain control over:
- Density
- Thickness
- Width
- Length
- Appearance
- Cell structure
- Dimensional stability
- Weight
- Physical properties
- Establish and monitor in-process quality checks.
- Investigate customer complaints, quality deviations and production rejections.
- Implement Root Cause Analysis (RCA), CAPA and corrective/preventive actions.

D. Maintenance & Machine Reliability

- Coordinate with the maintenance team to ensure maximum machine availability.
- Implement preventive and predictive maintenance schedules for:
- EPE extrusion lines
- Extruders
- Die systems
- Cooling systems
- Winding systems
- Cutting equipment
- Compressors
- Electrical systems
- LPG/gas systems
- Utility equipment
- Monitor machine breakdowns and downtime.
- Conduct breakdown analysis and ensure permanent corrective action.
- Maintain critical spare-parts inventory.

E. Safety & Compliance

- Make plant safety the highest operational priority.
- Ensure strict compliance with applicable factory, fire, electrical, LPG/gas and environmental safety requirements.
- Conduct regular safety inspections and toolbox meetings.
- Ensure proper housekeeping.
- Monitor LPG/gas handling, storage, pipelines and associated safety systems.
- Ensure availability and functionality of:
- Gas detection systems
- Fire extinguishers
- Fire hydrant/fire-fighting systems
- Emergency exits
- Emergency stop systems
- Electrical safety systems
- Earthing/anti-static arrangements
- Ventilation systems




- Immediately report and escalate unsafe conditions, incidents and near misses.
- Conduct emergency drills and ensure employees understand emergency procedures.

F. Manpower Management

- Plan manpower requirements according to production schedules.
- Supervise operators, helpers, technicians, supervisors and other plant personnel.
- Ensure proper allocation of manpower across shifts.
- Monitor attendance, discipline, productivity and overtime.
- Train employees on machine operation, quality, safety and work procedures.
- Develop multi-skilled operators wherever possible.
- Maintain proper shift handover and communication systems.
- Take necessary action against absenteeism, indiscipline and repeated performance issues in coordination with HR.

G. Cost & Productivity Control

The Plant Manager will be responsible for continuously improving plant economics.

Monitor and control:

- Raw material consumption
- LPG consumption
- Electricity consumption
- Manpower cost
- Scrap/rejection
- Maintenance cost
- Packaging cost
- Overtime
- Production per machine/hour
- Production per manpower
- Overall conversion cost

Develop initiatives to reduce cost per kg / cost per meter while maintaining required product quality.

H. Planning & Dispatch Coordination

- Coordinate with sales, planning, stores and dispatch teams.
- Prepare production plans based on confirmed orders and inventory requirements.
- Ensure finished goods are produced and made available as per dispatch schedule.
- Maintain appropriate finished-goods inventory.
- Escalate production constraints that may affect customer deliveries.

I. MIS & Reporting

Submit regular management reports covering:

- Daily production
- Machine-wise production
- Production efficiency
- Scrap/rejection
- Raw material consumption
- LPG consumption
- Electricity consumption
- Machine downtime
- Maintenance activities
- Quality issues
- Manpower/attendance
- Safety incidents
- Pending orders
- Dispatch readiness
- Key improvement initiatives

The Plant Manager should be able to present data-driven analysis and corrective-action plans to management.

3. Key Performance Indicators (KPIs)

The Plant Manager's performance will be measured against defined plant KPIs, including:

- Production achievement vs. plan
- Machine utilization
- Production efficiency
- Scrap/rejection percentage
- Raw material yield
- LPG consumption per kg of output
- Electricity consumption per kg of output
- Conversion cost per kg
- Machine downtime
- On-time production and dispatch readiness
- Customer complaints and quality rejection
- Manpower productivity
- Attendance and absenteeism
- Safety incidents / near misses
- Preventive maintenance compliance
- Continuous improvement savings

4. Required Qualification

- Diploma / B.E. / B.Tech. in Mechanical, Production, Plastics, Polymer, Electrical or related engineering discipline.
- Additional qualification in Operations / Production Management will be an advantage.

5. Experience

- 5–10 years of relevant manufacturing experience, preferably in EPE, PE foam, plastic extrusion, polymer processing, packaging or a similar continuous manufacturing environment.
- Minimum 3–5 years in a supervisory/managerial plant operations role.
- Experience handling production teams and multiple shifts is preferred.
- Hands-on experience with extrusion/process machinery will be strongly preferred.

6. Technical & Managerial Skills





The candidate should have:

- Strong understanding of extrusion and polymer processing.
- Practical knowledge of EPE foam manufacturing.
- Ability to understand and control process parameters.
- Strong production planning and execution skills.
- Knowledge of preventive and breakdown maintenance.
- Good understanding of industrial safety.
- Strong manpower handling and leadership skills.
- Cost-control and productivity improvement mindset.
- Ability to analyze production data and identify deviations.
- Problem-solving and Root Cause Analysis skills.
- Good Excel/MIS/reporting skills.
- Strong communication and coordination abilities.
- Ability to work in a fast-paced manufacturing environment.

7. Expected Leadership Behaviour

The Plant Manager is expected to:

- Lead from the shop floor rather than operate only from the office.
- Maintain robust discipline without compromising employee safety and dignity.
- Make decisions based on data, process knowledge and facts.
- Identify problems proactively rather than waiting for management escalation.
- Take ownership of production, quality, manpower and plant performance.
- Develop supervisors and operators into a stronger production team.
- Maintain clear communication between production, maintenance, quality, stores, dispatch and management.
- Continuously look for opportunities to improve productivity, yield, quality, safety and cost.

8. First 90-Day Expectations

During the first 90 days, the Plant Manager should:

First 30 Days

- Understand the complete EPE manufacturing process.
- Study machines, manpower, products and production flow.
- Review current production and quality data.
- Identify major sources of downtime, scrap and inefficiency.
- Review safety and housekeeping practices.

31–60 Days

- Establish standardized production monitoring.
- Implement shift-wise production and downtime reporting.
- Identify top 5 production losses and prepare corrective-action plans.
- Strengthen preventive maintenance and quality controls.
- Improve shop-floor discipline.

61–90 Days

- Demonstrate measurable improvement in productivity/yield.
- Establish stable production KPIs.
- Reduce avoidable scrap and downtime.
- Improve manpower productivity.
- Establish a structured daily plant review system.
- Present a 6–12 month plant improvement roadmap to management.

9. Authority & Accountability

The Plant Manager will have operational authority over the plant's day-to-day activities and will be accountable for:

Production + Quality + Maintenance Coordination + Manpower + Safety + Productivity + Cost Control + Plant Discipline

Major capital expenditure, significant manpower decisions, changes in major processes and other management-level matters will be subject to approval from the management.

10. Working Conditions

- Full-time plant-based position.
- Willingness to work in shifts/extended hours when required by production or emergency situations.
- Regular presence on the manufacturing floor is expected.
- Must be comfortable working around industrial machinery, extrusion equipment and associated utilities.
- Strong focus on safety procedures.

11. Ideal Candidate Profile

We are looking for a hands-on manufacturing leader, not just an administrative plant manager.

The ideal candidate should be capable of walking into the plant, understanding why production is below target, identifying whether the issue is related to raw material, process parameters, machine condition, manpower, cooling, LPG, quality or planning, and leading the team to solve the problem.

Ownership, technical understanding, discipline, safety consciousness and continuous improvement mindset are essential.

Pay: ₹20,000.00 - ₹50,000.00 per month

Benefits:

- Flexible schedule
- Provident Fund

Work Location: In person

📌 Plant Manager (India)
🏢 Aaditya Foam Industries
📍 India