HOD-Production

GMIPL Hiring Toolkit Confidential

The HOD Production is the person who makes tonnage happen on the shopfloor every a CRCA plant with multiple interdependent lines production execution requires shift management discipline line speed optimisation yield consciousness manpower deployment efficiency and relentless SOP adherence. A weak production head directly results in lost tonnage low yield high non-prime generation and poor shopfloor discipline.

To lead daily production execution across all process lines - pickling cold rolling batch annealing skin pass slitting and CTL - ensuring target achievement yield optimisation quality compliance manpower discipline and safe operations. The HOD Production is accountable for converting the production plan into actual output with minimum deviation managing shift teams reducing delays enforcing process discipline and driving continuous improvement in productivity. This role demands a hands-on leader who is present on the shopfloor understands each process deeply and can motivate and hold teams accountable.

• Achieve daily and monthly production targets across all process lines. Track and report shift-wise output delays and deviations.
• Execute the rolling plan as provided by the planning department. Minimise plan deviations caused by production-side issues (delays changeovers operator errors).
• Optimise line speeds and throughput: rolling mill speed pickling strip speed annealing cycle time adherence skin pass productivity slitting/CTL line efficiency.
• Manage shift teams: deploy manpower across lines based on schedule and priorities. Ensure adequate coverage for all shifts including overtime and leave management.
• Drive yield improvement: monitor input-output at each process stage reduce trimming losses edge cracks crop ends and material damage. Track recovery % weekly.
• Minimise non-prime generation: identify and reduce sources of surface defects dimensional deviations and process-related downgrades. Target non-prime < 3% of FG.
• Enforce SOP adherence on every line: rolling parameters (reduction speed tension) pickling parameters (acid concentration temperature speed) annealing cycle adherence skin pass elongation slitting/CTL tolerances.
• Reduce production delays: categorise delays (mechanical electrical quality hold RM shortage changeover operator error) track daily and drive reductions with maintenance and planning.
• Ensure quality at source: production operators must check parameters and flag deviations. Not all quality control should depend on QA/QC - first-line responsibility is production.
• Manage batch annealing operations: furnace loading/unloading cycle setting (temperature soak time cooling) atmosphere control (hydrogen/nitrogen) and batch composition efficiency.
• Coordinate with maintenance for production-impacting repairs. Ensure maintenance windows are respected and production restarts on time.

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• Maintain safety and housekeeping standards on the shopfloor: PPE compliance safe operating procedures 5S discipline crane safety hot material handling.
• Conduct daily production meetings (morning start-of-shift review): review previous shift performance current shift plan and resolve issues.
• Drive OEE improvement through reduction of planned and unplanned stops speed losses and quality losses.
• Develop shift in-charges and line operators: build multi-skilling conduct operator training and maintain a competency matrix.

Experience Required: 14 16 years in production operations within flat steel / cold rolling / strip processing. At least 3 5 years as a production manager or senior production in-charge managing multiple lines.

Mandatory Industry Exposure: Mandatory: Cold rolling production (not just single finishing line). Must have hands-on experience with rolling mill operations annealing and at least one finishing process (skin pass/slitting/CTL).

Preferred Plant Types: Multi-line cold rolling plants (TPA). Should have managed shiftbased production with multiple process stages.

Education: B.E./ in Mechanical or Metallurgical Engineering.

Technical Skills: Understanding of cold rolling parameters (reduction tension speed roll gap control) annealing metallurgy (recrystallisation grain growth) skin pass parameters (elongation surface roughness) and pickling chemistry. Must understand how process parameters affect final product quality.

ERP / MIS Expectations: Should log production data in ERP use MIS for daily tracking and be comfortable with production dashboards. Not just an oral reporting person.

Leadership Capability: Has managed 40 100 operators and shift in-charges across multiple shifts. Can enforce discipline without being autocratic. Leads by presence and example on the shopfloor.

Communication: Can report production data clearly to Plant Head. Effective shopfloor communication in Hindi/Marathi. Can coordinate with planning quality and maintenance heads.

Reject if: (a) Only finishing line experience (slitting/CTL) without rolling or annealing. (b) Cannot explain basic cold rolling metallurgy or why annealing is needed. (c) Only worked in continuous process (not batch/reversing) if plant has reversing mill. (d) Poor shopfloor presence - sits in office and manages through reports only. (e) History of safety incidents under their watch.

JSW Steel (cold rolling production) Tata Steel (cold rolling/tinplate) AM/NS India Bhushan Steel Uttam Galva SAIL cold rolling units Essar Steel Nippon Steel India POSCO Maharashtra mid-sized CRCA processors and flat steel service centres with in-house cold rolling. Also consider candidates from aluminium or copper rolling if cold rolling production expertise is strong.

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