PLANT HEAD

Cable Lugs & Power Press Components | Copper & Aluminium Manufacturing

Greenfield Setup | Senior Leadership Role | 15+ Years Experience Required

Designation: Plant Head

Industry: Electrical Components Manufacturing

Product Focus: Cable Lugs & Power Press Components (Copper & Aluminium)

Location: Rajkot, Gujarat

Reporting To: Director

Experience Required: 15+ Years (relevant domain)

Employment Type: Full-Time | Permanent

Date of Requirement: Immediate/As Per Notice Period

ROLE OVERVIEW:

We are seeking a dynamic and experienced Plant Head to lead the establishment and operations of a new manufacturing facility specialising in copper and aluminium cable lugs and power press components. This is a rare leadership opportunity for a results-driven professional who possesses hands-on expertise in setting up a manufacturing plant from the ground up encompassing infrastructure planning, machinery procurement, process design, team building, and full-scale production ramp-up. The ideal candidate will be a self-starter with a proven track record in the electrical components or precision metal parts manufacturing sector and the ability to work with cross-functional stakeholders to translate business vision into operational reality.

KEY RESPONSIBILITIES:

1. Greenfield Plant Setup & Project Management:

- Lead end-to-end planning and execution of the new manufacturing facility from concept to commissioning.

- Collaborate with management on layout design, civil work coordination, and infrastructure readiness.

- Identify, evaluate, and procure machinery, tooling, and equipment for cable lug and power press operations.

- Define standard operating procedures (SOPs), safety norms, and production workflows from scratch.

- Coordinate with vendors, contractors, and regulatory bodies for utility connections, factory licences, and compliance.

2. Production & Operations Management:

- Oversee day-to-day plant operations including production planning, scheduling, and capacity utilisation.

- Drive production targets for copper and aluminium cable lugs and power press stamped components.

- Monitor and control raw material usage copper rods/strips, aluminium billets, and ancillary inputs.

- Manage press shop operations including die setting, tooling maintenance, and press cycle optimisation.

- Ensure timely dispatch of finished goods in line with customer delivery commitments.

3. Quality Assurance & Compliance:

- Establish quality control systems, inspection standards, and rejection/rework protocols.

- Ensure adherence to product specifications, dimensional tolerances, and customer quality norms.

- Drive implementation of quality certifications (ISI, ISO, RoHS or as applicable).

- Monitor metallurgical properties of copper and aluminium components and address deviations.

4. Team Leadership & Development:

- Recruit, train, and build a skilled workforce covering operators, supervisors, engineers, and QC staff.

- Define organisational structure for the plant and establish reporting hierarchies.

- Conduct regular performance reviews, skill gap assessments, and training programs.

- Foster a culture of safety, discipline, and continuous improvement on the shop floor.

5. Cost Control & Efficiency:

- Prepare and manage plant budgets including capex for setup and opex for ongoing operations.

- Track key metrics such as OEE (Overall Equipment Effectiveness), scrap rates, yield, and energy consumption.

- Implement lean manufacturing, 5S, and Kaizen initiatives to improve process efficiency.

- Optimise material procurement and inventory to minimise waste and working capital.

6. Statutory & Safety Compliance:

- Ensure full compliance with Factories Act, pollution control norms, and fire safety regulations.

- Implement and enforce EHS (Environment, Health & Safety) policies across the facility.

- Maintain all statutory records, registers, and licences as required by law.

- Conduct regular safety drills, audits, and near-miss reporting processes.

QUALIFICATIONS & EDUCATIONAL BACKGROUND:

Essential: B.E./B.Tech in Mechanical, Electrical, Production, or Metallurgical Engineering.

Preferred: M.E./MBA in Operations/Manufacturing Management.

Certifications: Lean/Six Sigma (Green Belt or above) preferred; ISO internal auditor a plus.

EXPERIENCE REQUIREMENTS:

- 15+ years of relevant experience in the manufacture of cable lugs, electrical connectors, or power press components.

- Demonstrated experience in setting up a new manufacturing plant or production line from scratch this is a critical requirement.

- Hands-on exposure to cold forging, hot forging, or power press operations for copper and aluminium components.

- Experience managing press capacities ranging from 10 tonnes to 300 tonnes or higher.

- Sound knowledge of copper and aluminium properties, forming behaviour, and surface treatment processes (tinning, silvering, etc.).

- Prior experience in die & tool management, press maintenance scheduling, and tool life optimisation.

- Track record of managing teams of 50+ employees at a manufacturing facility.

- Experience dealing with MSME-scale or mid-size manufacturing operations preferred.

TECHNICAL SKILLS & DOMAIN KNOWLEDGE:

Manufacturing & Process:

- Power press & stamping operations.

- Cable lug fabrication (ring, pin, fork, ferrules).

- Die design, tooling & maintenance.

- Copper & aluminium forming & heat treatment.

- Surface finishing tinning, silvering, anodising.

- Layout planning & material flow design.

Management & Systems:

- Production planning & scheduling (ERP/MRP).

- Quality management systems (QMS, SPC, FMEA).

- Lean manufacturing, 5S, Kaizen, TPM.

- Budgeting, capex planning & cost control.

- Vendor development & procurement coordination.

- EHS systems & statutory compliance.

BEHAVIOURAL COMPETENCIES:

- Entrepreneurial mindset with the ability to build and lead from the ground up.

- Strong decision-making and problem-solving skills under operational pressure.

- Excellent leadership, people management, and team development capabilities.

- High integrity, accountability, and results orientation.

- Effective communication with management, vendors, customers, and shop floor staff.

- Adaptability and resilience in navigating ambiguous, high-growth environments.

COMPENSATION & BENEFITS:

Compensation will be commensurate with experience and industry benchmarks. The organisation offers a competitive package including:

- Fixed CTC as per market standards for the role and experience level.

- Performance-linked incentive/annual bonus.

- Statutory benefits as per applicable labour laws (PF, ESIC, Gratuity).

- Accommodation assistance/relocation support (if applicable).

- Opportunity to build a plant from the ground up and grow with the organisation.

INSTRUCTIONS FOR HR AGENCY:

This document is issued for recruitment purposes only. Unauthorised distribution is prohibited.