Head - Plant Operation

Plant Operations Head

Position Summary:

The Plant Operations Head is responsible for leading end-to-end manufacturing operations, ensuring achievement of business objectives related to Safety, Quality, Delivery, Cost, Productivity, and People Development. The role provides strategic and operational leadership for manufacturing, engineering, supply chain coordination, quality systems, project execution, operational excellence, and regulatory compliance while driving sustainable profitability and customer satisfaction.

Key Responsibilities:

Manufacturing Operations Leadership:

- Lead overall plant operations to achieve Annual Operating Plan (AOP), business targets, and strategic initiatives.

- Ensure consistent achievement of PQCDSM (Productivity, Quality, Cost, Delivery, Safety, and Morale) objectives.

- Drive operational excellence through effective planning, organizing, staffing, directing, and controlling plant activities.

- Ensure reliable customer supply through close coordination with Supply Chain, Sales, Marketing, Procurement, and Commercial teams.

- Monitor and improve plant capacity utilization, OEE, productivity, and operational efficiency.

Financial & Business Management:

- Own plant P&L performance and deliver budgeted profitability targets.

- Prepare annual budgets, operating plans, KPIs, and long-range business plans.

- Drive gross margin improvement, cost optimization, value engineering, and productivity enhancement initiatives.

- Implement variance analysis, cost controls, and financial governance mechanisms.

- Ensure strong internal controls, risk management controls (RCM), and commercial compliance.

Safety, Health & Environment (SHE):

- Establish and maintain world-class safety culture with zero-harm objectives.

- Ensure compliance with EHS regulations, statutory requirements, and corporate standards.

- Lead safety audits, risk assessments, incident investigations, and corrective actions.

- Promote environmental sustainability and energy conservation initiatives.

Quality & Compliance Management:

- Ensure compliance with Quality Management Systems (QMS), Food Safety Management Systems (FSMS), GMP, HACCP, and customer requirements.

- Lead preparation and successful completion of customer, regulatory, and certification audits.

- Maintain compliance with standards such as ISO 9001, ISO 14001, ISO 45001, FSSC 22000, BRC, SA8000, and other applicable certifications.

- Drive continuous quality improvement through SPC, SQC, CAPA, and root cause analysis.

Engineering & Maintenance Excellence:

- Lead engineering, utilities, maintenance, and reliability functions.

- Implement TPM, preventive maintenance, predictive maintenance, and asset management programs.

- Drive automation, digitization, PLC/SCADA improvements, and technology upgrades.

- Deliver energy conservation and technical efficiency improvement projects.

Project Management & Expansion:

- Lead greenfield and brownfield projects from concept to commissioning.

- Manage CAPEX, OPEX, and strategic investment projects.

- Coordinate project design, engineering, procurement, installation, validation, and start-up activities.

- Ensure projects are delivered on time, within budget, and meeting business objectives.

Supply Chain & Customer Service:

- Collaborate with procurement and supply chain teams to ensure uninterrupted material availability.

- Optimize inventory, warehousing, logistics, and distribution operations.

- Support new product launches, technology transfers, and market expansion initiatives.

- Maintain high service levels and customer satisfaction.

Operational Excellence & Continuous Improvement:

- Drive Lean Manufacturing, TPM, Six Sigma, Kaizen, 5S, WCM, and continuous improvement programs.

- Establish a performance-driven culture using KPIs, dashboards, and review mechanisms.

- Lead productivity improvement and waste reduction initiatives.

- Promote best practices and benchmark performance across sites.

People Leadership & Industrial Relations:

- Build, mentor, and develop high-performance leadership and operational teams.

- Drive performance management, succession planning, and capability development programs.

- Manage industrial relations, union negotiations, long-term settlements, disciplinary actions, and employee engagement initiatives.

- Foster a culture of accountability, collaboration, and continuous learning.

Regulatory & Statutory Compliance:

- Ensure compliance with all government, statutory, environmental, labor, and industry regulations.

- Manage licenses, permits, and approvals from relevant authorities.

- Coordinate with regulatory bodies, auditors, and external agencies.

Key Performance Indicators (KPIs):

- Safety Performance (TRIR, LTIFR, Near Miss Closure)

- Production Achievement vs Plan

- OEE Improvement

- Customer Service Level / OTIF

- Manufacturing Cost per Unit

- Gross Margin Improvement

- Quality Performance (FPY, Customer Complaints, COPQ)

- Inventory & Working Capital Optimization

- Energy and Utility Efficiency

- Project Delivery (Cost, Time, Scope)

- Employee Engagement & Capability Development

Qualifications:

- B.Tech./B.E. in Chemical Engineering, Mechanical Engineering, Industrial Engineering, or related discipline.

- MBA/PGDBA preferred.

- Certifications in TPM, Six Sigma, Lean Manufacturing, Project Management, or Operational Excellence are desirable.

Experience:

- 20+ years of progressive manufacturing leadership experience.

- Proven experience in Chemical, FMCG, Personal Care, Home Care, Food, Pharma, Nutraceutical, or Consumer Products industries.

- Demonstrated success in multi-site operations, plant leadership, large-scale project execution, operational excellence, and P&L management.

- Experience in both multinational and promoter-driven organizations preferred.

Reporting Structure:

- Reports To: CEO / Managing Director / Business Head

- Direct Reports: Production, Engineering, Maintenance, Quality, Supply Chain, EHS, Projects, HR, Warehouse, and Utilities Heads.

Leadership Competencies:

- Strategic Thinking

- Business Acumen

- Results Orientation

- Change Management

- Stakeholder Management

- Team Building & Coaching

- Decision Making

- Problem Solving

- Cross-functional Collaboration

- Customer Focus