Head – Plant Operations

Job Description

FO-HR-02

Revision: R00

INTERNAL Valid as of: 04/25

VHEI/IMS/DP-HR & ADMIN R05 1

Date July 2025

Job title Head

Department name Plant Operation

Reporting to CEO

Purpose

To lead and oversee all aspects of plant operations ensuring efficient production optimal

resource utilization safety compliance and alignment with organizational goals. The Head of Plant

Operations is responsible for driving operational excellence improving productivity managing

cross-functional teams and ensuring timely delivery of high-quality products in a cost-effective

manner.

Tasks / Roles and Responsibilities

1. Study Technical Specifications Drawings & applicable standards. Devise suitable production

process/flow

a) Lead and monitor complete plant production activities to achieve daily weekly and

monthly targets.

b) Ensure efficient operation of fabrication machining welding assembly and heavy

engineering processes

c) Review manpower deployment workflow machine utilization and productivity

improvement activities.

d) Oversee safety practices ensure statutory compliance and enforce a zero-incident

culture.

2. Co ordinate with Client/TPI/QC/QA for suitable development of QAP/ITP WPS PQR.

a) Prepare manufacturing schedule and align with client/delivery requirements

b) Identify and assign resources plant & equipment manpower consumables etc

c) Assign align and manage Shift operations

d) Quick close out of break down maintenance. Avoid down time.

3. Drive continuous improvement initiatives: Lean Kaizen 5S and process optimization.

4. Handle audits (ISO safety customer audits) and ensure timely closure of audit observations.

Job Description

FO-HR-02

Revision: R00

INTERNAL Valid as of: 04/25

VHEI/IMS/DP-HR & ADMIN R05 2

5. Allocation of work to different work bays / team to get optimum output.

6. Manage Supervisory and On the job work manpower.

7. Ensure timely availability of all input materials and consumables

8. Ensure congenial work relationship with all departments and within Production department

9. Ensure 100% work place safety of all assets including manpower.

10. Ensure 100% compliance to Quality Standards.

11. Interact with Client / TPI for in process inspection and final clearance.

12. Manage sub contractors outsourcing agencies.

13. Co ordinate with Maintenance for effective implementation of Preventive maintenance.

14. Prepare and circulate Daily Weekly and Monthly progress reports with projections.

15. Initiate steps to control Consumable wastage and reduction by identifying alternate methods.

16. Be part of Review meetings with appropriate data and mitigation plan if called for.

Job requirements (education experience additional qualifications)

Education:

Bachelors degree in Mechanical Electrical Industrial or Production Engineering/Diploma with

extensive experience.

Masters degree (MBA/PGDM) in Operations Management or Industrial Management is an

added advantage.

Professional certifications in Lean Manufacturing Six Sigma or Plant Management will be

preferred.

Experience: Minimum 25 years for Graduate Engineer / 23 years for Diploma Engineer in Fabrication

industry

Job Description

FO-HR-02

Revision: R00

INTERNAL Valid as of: 04/25

VHEI/IMS/DP-HR & ADMIN R05 3

Mandatory Skills:

In-depth understanding of fabrication industry processes

Strong leadership and team management for large workforce (200 workmen)

Proven experience in managing end-to-end plant operations

Excellent understanding of safety protocols and maintaining a clean safety record

Expertise in production planning scheduling and resource allocation

Strong coordination with cross-functional teams (QA/QC Maintenance SCM etc.)

Proficiency in reading technical specifications drawings and manufacturing standards

Preferred Skills:

1. Hands-on experience in:

a) Plate rolling operations

b) Various welding techniques (SAW SMAW GMAW GTAW FCAW)

c) Material handling with EOT cranes and gantries

d) Machine shop and fabrication equipment

2. Familiarity with Indian and international material/production standards

a) Implementation knowledge of:

b) 5S

c) Kaizen

d) Just-In-Time (JIT)

e) Total Quality Management (TQM)

3. Exposure to Lean Manufacturing and Six Sigma methodologies.

4. Experience managing subcontractors and outsourcing agencies.

5. Capability in reducing consumable wastage through alternative methods.

6. Shift-wise productivity and output metrics.

KPIs

1. Production output vs. target achievement

2. On-time delivery adherence rate

3. Resource utilization efficiency (manpower machinery consumables)

4. Downtime frequency and breakdown closure time

5. Safety incident frequency rate (Zero LTI goal)

6. Quality compliance Rejection/Rework percentage

7. Preventive maintenance schedule adherence

8. Cost savings achieved through process improvements or waste reduction

9. Client/TPI satisfaction score (based on inspection reports and audits)

10. Shift-wise productivity and output metrics