– Head Manufacturing, EHS & Logistics

Position: Head – Manufacturing, EHS & Logistics

Grade: E7B

Location: Mumbai

Department: Manufacturing

Function: Manufacturing

Reporting To: Managing Director (MD)

Experience: 15–20 Years

Qualification: MBA – Operations or equivalent

Position Overview

We are looking for an experienced Head – Manufacturing, EHS & Logistics to lead and transform the organization's manufacturing, EHS and logistics operations into a safe, efficient, technology-enabled and cost-effective operating ecosystem.

The role will be responsible for driving operational excellence, manufacturing productivity, automation, digitalization, manpower optimization, cost efficiency, capacity utilization, EHS compliance, logistics effectiveness and continuous improvement .

Key Responsibilities

1. Manufacturing & Operational Excellence

- Lead end-to-end manufacturing operations including blending, filling, packaging, warehousing interface and dispatch .
- Ensure achievement of production, quality, cost, safety and delivery targets.
- Optimize plant capacity, equipment utilization, production scheduling and manufacturing processes.
- Drive improvement in OEE, yield, downtime, batch cycle time and process losses .
- Implement Lean Manufacturing, TPM, 5S, Kaizen and continuous improvement initiatives.
- Establish standardized operating processes and ensure process discipline across plants.
- Evaluate in-house manufacturing vs. outsourcing opportunities based on cost, capacity and strategic requirements.

1. Automation & Digitalization

- Develop and implement manufacturing automation and digital transformation roadmaps.
- Identify opportunities for automation across manufacturing, material handling, filling, packaging and logistics.
- Drive adoption of PLC/SCADA, automated filling and packaging, Barcode/RFID, automated material handling, IoT, predictive maintenance and digital production monitoring .
- Leverage ERP/MES and digital platforms for production visibility, traceability and decision-making.
- Establish real-time operational dashboards and data-driven performance management.
- Evaluate AI, robotics and intelligent automation opportunities.
- Prepare business cases and ROI models for technology investments.

1. Manpower Optimization & Productivity

- Analyze manpower productivity and workload across Manufacturing, EHS and Logistics.
- Develop optimum manpower models based on production volume, capacity and automation.
- Improve productivity through automation, multi-skilling, job redesign and process simplification.
- Optimize permanent, contract and outsourced workforce.
- Establish and monitor productivity metrics including output/man-hour, manpower cost/unit, workforce utilization and contract manpower productivity.

1.



Cost Optimization & Operational Excellence

- Lead manufacturing and logistics cost optimization initiatives.
- Drive cost reduction across raw materials, packaging, energy, manpower, maintenance, freight, warehousing, process losses, waste and rework .
- Establish cost-per-unit and conversion-cost benchmarks.
- Drive energy efficiency and utility-cost reduction.
- Monitor plant budgets and actual expenditure.
- Lead annual cost productivity and value-engineering initiatives.
- Ensure CAPEX proposals are supported by clear ROI, payback and productivity perks.

1. EHS & Process Safety

- Develop and implement the organization's EHS strategy and governance framework.
- Ensure compliance with applicable Factory, Environment, Fire, Hazardous Chemical and other statutory requirements .
- Drive a strong safety culture across manufacturing operations.
- Implement HIRA, risk assessments, permit-to-work, emergency response and contractor safety systems .
- Drive reduction in incidents, near misses and unsafe conditions.
- Ensure safe chemical handling, storage, hazardous-waste management, emissions control and environmental protection.
- Conduct EHS audits and ensure timely closure of corrective actions.
- Implement digital tools for EHS reporting and compliance tracking.

1. Logistics & Distribution

- Lead logistics and dispatch operations to achieve OTIF delivery and optimum logistics cost.
- Optimize transportation routes, vehicle utilization, load planning and freight costs.
- Drive logistics digitalization through GPS tracking, digital POD, shipment visibility and analytics.
- Optimize 3PL operations and logistics processes.
- Establish logistics productivity and cost benchmarks.
- Ensure safe handling and transportation of lubricant products.

1. Supply Chain & Inventory Optimization

- Work with Supply Chain, Procurement, Sales and Finance to align production, inventory and demand.
- Optimize raw material, packaging and finished-goods inventory.
- Reduce stock-outs, excess inventory, slow-moving and obsolete inventory.
- Improve production planning and schedule adherence.
- Drive data-based operational decision-making.

1. CAPEX, Projects & Technology

- Lead plant modernization, expansion and automation projects.
- Identify technology-led capacity enhancement opportunities.
- Evaluate new technologies and equipment for productivity and cost benefits.




- Ensure projects are delivered within approved cost, timeline, quality and safety parameters.
- Conduct post-implementation reviews to measure ROI and benefits realization.

1. People & Organization Development

- Build a high-performing and future-ready manufacturing organization.
- Define optimum organization structure and manpower models.
- Develop technical, digital and leadership capabilities of plant teams.
- Establish succession plans for critical operational positions.
- Promote multi-skilling and cross-functional capability.
- Build a culture of accountability, innovation and continuous improvement.

Cross-Functional Responsibilities
- Partner with B2B / Institutional Sales and Key Account teams to understand customer requirements, demand patterns and new business opportunities.
- Collaborate with B2C, Marketing and Commercial teams for capacity, product mix and seasonal demand planning.
- Work with IT / Technology / Digital teams on automation, ERP/MES, IoT, predictive maintenance, analytics and AI-enabled operational improvements.
- Partner with Technical Services for product development, trials, scale-up, process validation and commercialization.
- Collaborate with Quality to ensure right-first-time manufacturing, batch consistency and timely resolution of quality issues.
- Work closely with Supply Chain and Procurement on production planning, raw-material availability and inventory strategy.
- Partner with Finance for cost optimization, budgeting, productivity and CAPEX ROI.
- Work with HR on manpower planning, productivity, organization structure and workforce optimization.
- Lead cross-functional operating reviews and resolve operational bottlenecks.
- Act as the key manufacturing interface for new customer acquisition, major OEM opportunities, product launches and business expansion projects .

Qualifications & Experience
- MBA – Operations or equivalent qualification.
- 15–20 years of relevant experience in Manufacturing, Plant Operations and Logistics.
- Strong leadership experience in manufacturing and plant operations.
- Strong exposure to EHS, logistics, automation, operational excellence and cost optimization .
- Experience in people management and Industrial Relations (IR) is mandatory .
- Experience in driving productivity, digitalization, CAPEX and continuous improvement initiatives.
- Strong cross-functional stakeholder management and leadership skills.

Key Competencies Manufacturing | Plant Operations | EHS | Logistics | Operational Excellence | Lean Manufacturing | TPM | Automation | Digitalization | ERP/MES | Cost Optimization | CAPEX | Supply Chain | Inventory Management | People Management | Industrial Relations | Continuous Improvement

📌 Head Manufacturing, EHS & Logistics (Mumbai)
🏢 Tu0026M Services Consulting
📍 Mumbai