Location: Bharuch, Gujarat

Experience: 1520 Years

Qualification: B.E./B.Tech – Metallurgy, Mechanical, Chemical or Electrical Engineering (Metallurgy / Chemical preferred)

Industry: Copper / Non-Ferrous Metals / Metal Manufacturing / Recycling

About the Role

We are looking for an experienced Head of Plant Operations to lead the complete operations of a large-scale copper manufacturing plant in Bharuch.

The position will have end-to-end responsibility for project execution, plant commissioning, production, engineering, maintenance, quality, manpower management, operational excellence, safety and overall plant performance.

The incumbent will work closely with the Promoters, CEO/Management and functional heads to ensure successful project execution, smooth commissioning, achievement of production targets, operational efficiency, product quality and cost optimization.

The role requires a strong manufacturing leader who has experience in setting up, commissioning and managing large-scale metal processing or copper manufacturing facilities.

Key Responsibilities

1. Project Execution & Plant Commissioning

- Lead end-to-end project execution, installation, erection and commissioning of the copper manufacturing plant.
- Coordinate with EPC contractors, equipment suppliers, engineering consultants and technical partners.
- Ensure timely completion of civil, mechanical, electrical, instrumentation and utility installations.
- Drive equipment trials, process validation, trial production and commercial commissioning.
- Establish operational readiness, SOPs, systems and processes before plant stabilization.
- Monitor project timelines, budgets, resource deployment and execution milestones.
- Resolve technical and execution bottlenecks to ensure timely project completion.

2. Production & Plant Operations

- Take complete ownership of day-to-day plant operations and production activities.
- Develop production plans and ensure achievement of daily, monthly and annual production targets.
- Manage the complete manufacturing process, including raw material processing, smelting, refining, casting and downstream operations, as applicable.
- Monitor plant capacity utilization, yield, recovery, throughput and product quality.
- Optimize process parameters, production efficiency and equipment utilization.
- Ensure consistent production output while maintaining quality and operational standards.
- Drive process improvements and reduce production losses, rejections and downtime.

3. Engineering & Maintenance

- Lead mechanical, electrical, instrumentation and utility maintenance functions.
- Establish preventive, predictive and breakdown maintenance systems.
- Ensure maximum equipment availability and minimize unplanned downtime.
- Oversee maintenance of furnaces,



processing equipment, material handling systems, electrical installations and utilities.
- Drive reliability improvement, equipment performance and maintenance cost optimization.
- Ensure availability of critical spares and maintenance resources.

4. Process Optimization & Operational Excellence

- Drive continuous improvement in manufacturing processes, productivity and operational efficiency.
- Optimize metal recovery, material yield, energy consumption and conversion costs.
- Identify process bottlenecks and implement corrective and preventive measures.
- Establish production KPIs, process control systems and performance dashboards.
- Drive lean manufacturing, 5S, TPM and operational excellence initiatives.
- Benchmark plant performance against industry standards.

5. Raw Material & Production Planning

- Coordinate with procurement and commercial teams for raw material planning and availability.
- Ensure optimum utilization of copper scrap, concentrates, cathodes or other relevant feedstock.
- Establish material reconciliation systems covering input, output, WIP, finished goods and process losses.
- Optimize production planning based on raw material availability, customer requirements and plant capacity.
- Monitor metal recovery, material losses and inventory movement.

6. Manpower & Organizational Management

- Lead the complete plant workforce, including production, engineering, maintenance, quality, utilities and operational support teams.
- Develop the plant organization structure and manpower requirements.
- Recruit, train and develop technical and operational teams.
- Establish clear KRAs, KPIs and performance management systems.
- Manage shift operations, workforce productivity, discipline and industrial relations.
- Build a strong second-line leadership team and ensure operational accountability.

7. Quality & Process Control

- Ensure adherence to product specifications and customer quality requirements.
- Establish quality control systems across all stages of manufacturing.
- Coordinate with quality and laboratory teams for testing, process validation and product certification.
- Drive reduction in process rejections, customer complaints and quality deviations.
- Ensure consistent product quality and manufacturing standards.

8. HSE, Environment & Statutory Compliance

- Establish a strong safety culture across the plant.




- Ensure compliance with industrial safety, environmental and pollution control regulations.
- Oversee EHS systems, risk assessments, emergency response and safety audits.
- Ensure compliance with factory licences, environmental clearances and other statutory requirements.
- Drive safe operating practices, accident prevention and environmental sustainability.

9. Cost Control & Operational Performance

- Own plant-level operational budgets and manufacturing cost performance.
- Monitor conversion costs, power consumption, fuel, manpower and maintenance expenses.
- Drive productivity improvement and cost reduction initiatives.
- Work closely with finance and commercial teams to improve plant profitability.
- Review production efficiency, yield, recovery, downtime and overall equipment effectiveness.
- Ensure efficient utilization of CAPEX, plant infrastructure and operational resources.

10. Leadership & Management Reporting

- Act as the overall operational leader of the manufacturing facility.
- Work closely with the Business head, Promoters and senior management on operational strategy and business growth.
- Establish daily, weekly and monthly operational review mechanisms.
- Present plant performance, production MIS, project progress and operational challenges to management.
- Coordinate with finance, procurement, HR, commercial and sales functions.
- Drive a culture of ownership, accountability, safety and operational excellence.

Desired Candidate Profile

- B.E./B.Tech in Metallurgy, Mechanical, Chemical or Electrical Engineering.
- 15–20 years of experience in large-scale manufacturing, metals, copper, non-ferrous metals or metal recycling.
- Strong experience in managing complete plant operations with responsibility for production, engineering, maintenance and manpower.
- Experience in setting up, project execution, installation and commissioning of manufacturing plants will be highly preferred.
- Strong understanding of copper manufacturing, smelting, refining, casting and metal processing technologies.
- Experience managing large-scale industrial teams and multi-shift manufacturing operations.
- Solid exposure to production planning, process optimization, yield improvement and cost control.
- Experience in managing EPC contractors, equipment suppliers and technical consultants.
- Strong understanding of industrial safety, environmental compliance and statutory requirements.
- Proven ability to drive plant productivity, operational efficiency and manufacturing excellence.
- Strong leadership, problem-solving and cross-functional management capabilities.
- Should be comfortable working in a high-growth, project-driven and operationally intensive manufacturing environment.

📌 Copper Plant | Operations Head | Project & Production (Bharuch)
🏢 Wikilabs India
📍 Bharuch