Position Title: Head Production - Plant (Polymer)

Department: Manufacturing / Operations

Reports To: Plant Head

Location: Pune

Job Purpose:

To lead and manage the complete production operations of the Polymer Manufacturing Plant by ensuring safe, cost-effective, high-quality, and timely production. The role is responsible for achieving business objectives related to Productivity, Quality, Cost, Delivery, Safety, and Morale (PQCDSM), driving continuous improvement initiatives, optimizing plant resources, managing cross-functional coordination, and ensuring sustainable manufacturing excellence.

Organizational Structure

Key Responsibilities:

1. Production Planning & Execution

- Develop and execute monthly, weekly, and daily production plans based on customer demand and business requirements.
- Ensure optimal utilization of manpower, machines, materials, and utilities.
- Monitor production output against targets and take corrective actions to achieve productivity goals.
- Lead manufacturing operations to achieve annual business targets related to volume, quality, and cost.
- Track and improve Overall Equipment Effectiveness (OEE), capacity utilization, and line efficiencies.
- Ensure adherence to production schedules while maintaining quality standards.

2. Production Control & Capacity Management

- Work closely with PPC and Supply Chain teams to ensure smooth material planning.
- Review capacity utilization and identify bottlenecks affecting productivity.
- Develop contingency plans to meet production requirements during equipment breakdowns or material shortages.
- Monitor production loading and balancing across manufacturing lines.
- Optimize changeover times and improve throughout.

3. Polymer Manufacturing Operations Management





- Lead all polymer processing activities including compounding, molding, extrusion, blending, finishing, and packaging operations.
- Ensure process stability and adherence to defined process parameters.
- Monitor critical polymer manufacturing parameters affecting product quality and productivity.
- Drive process standardization across production lines.
- Ensure compliance with customer specifications and regulatory requirements.

4. Continuous Improvement & Operational Excellence

- Drive Lean Manufacturing, TPM, Kaizen, Six Sigma, and Industry 4.0 initiatives.
- Identify improvement opportunities in cycle time, productivity, yield, and process capability.
- Partner with Manufacturing Engineering for automation and process enhancement projects.
- Lead waste elimination and value stream improvement initiatives.
- Implement digital monitoring systems for real-time production control.

5. Cost Management & Productivity Improvement

- Achieve annual cost reduction targets through process optimization and resource efficiency.
- Improve material yield and reduce consumption losses.
- Monitor and control variable manufacturing costs.
- Drive initiatives for:
- Energy conservation
- Consumable cost reduction
- Scrap reduction
- Manpower productivity enhancement
- Support budgeting and production cost planning activities.

6. Quality Management





- Ensure adherence to customer quality requirements and internal quality systems.
- Monitor key quality metrics including:
- Customer PPM
- In-House Rejection (IHR)
- Scrap Cost
- Rework Cost
- First Pass Yield
- Lead root cause analysis and corrective actions for process defects.
- Support internal and external quality audits.
- Implement process controls and statistical quality monitoring systems.

7. Safety, Setting & Compliance

- Drive a strong safety culture across the plant.
- Ensure compliance with EHS, statutory, and environmental requirements.
- Monitor implementation of safety systems, PPE compliance, permit systems, and risk assessments.
- Lead accident prevention initiatives and near-miss management.
- Ensure zero major safety incidents and regulatory non-compliance.
- Support sustainability and environmental improvement programs.

8. CAPEX & Project Management

- Identify and propose CAPEX projects for productivity, automation, quality improvement, and cost optimization.
- Support project planning, execution, commissioning, and stabilization.
- Review project ROI and productivity benefits.
- Participate in new product and process industrialization activities.
- Ensure projects are delivered within budget and timelines.

9. Cross Functional Coordination

10. Team Leadership & Talent Development

- Lead and develop production teams across shifts and departments.
- Build leadership capability among frontline managers and supervisors.
- Conduct performance reviews and succession planning.
- Identify training and development needs.
- Develop a multi-skilled workforce and improve employee engagement.
- Foster a culture of accountability, ownership, and continuous improvement.

📌 Head Production - Plant (Polymer Division) (Maharashtra)
🏢 Varroc
📍 Maharashtra