Plant Head - Tyre Business

Designation : Plant Head - OHT (Off road Tyre or Off Highway Tyre)

Experience : 20 years+ in OTR Tyre production

Location : Madurai

Responsible for: Operations of our OHT Plant with key focus to production and maintenance. Knowledge in managing over all plant operations including materials, quality ,facility, people, union and stuatory authority.

Reporting to : Vice president operations

Key Responsibilities:

- Production plan adherence, module wise (OTIF, Cost)

- Reduction in Cost (consumables, energy, inventory)

- Plant utilization, module wise

- Reduction in internal rejections and rework (tyre scrap, compound scrap, fabric scrap)

- Reduction in plant accidents

- Internal audit NC

- Building the next line

- Employee engagement in the plant

- Plant productivity

- MIS & reporting (SAP)

- Progress on key initiatives - to define

- Add technical process

Key Responsibilities:

Planning & Budgeting

- Plan, implement and monitor the production schedule for the Plant based on the Sales/ Demand plan and in coordination with the Planning team

- Forecast and prepare the annual budgets for their respective plants

- Coordinate, set up and implement standard operating procedure for all production operations

- Plan for manpower requirement (workmen and contract labour) and work with HR to ensure availability of workforce module wise, on a timely basis.

- Plan for materials/ equipment's required for carrying out the production as per plan and coordinate with Plant Engineering and Supply Chain teams

- Plan for shutdown maintenance in consultation with the Plant Engineering Team

Production Operations

- Ensure achievement of production target as per production plan and standards with optimum utilization of resources and good coordination and teamwork across all the functions and areas

- Continuously monitor various production parameters like quantity and quality of material, machine utilization, uptime, scrap etc. to proactively address likely issues

- Ensure other departments at the plant are updated well in time in case of any deviations

- Coordinate with Plant Engineering department for resolution of any technical problem such as breakdown of machinery/ equipment etc.

- Work with Technical Process and Compound / Materials team to address bottlenecks and enhance/maintain the yield and make improvements in the process to get better efficiency

- Monitor material consumption & inventory levels at the plant to ensure no disruption in the production process

- Ensure all material requisition is raised in a timely manner

- Identify and take necessary actions for continuous improvement in production process

- Deploy initiatives as identified for improving plant efficiency and productivity

- Ensure compliance to the defined processes and standards ensuring zero non-conformity in internal and external audits

Production Quality

- Ensure reduction in in-process rejections and internal rework so as to attain efficient operations and cost reduction

- Continuously monitor resolution of frequent errors

- Liaison with the Quality team and R&D team to address chronic issues

Efficiency & Productivity

- Ensure effective management of production lines to ensure maximum capacity utilization (OEE) so as to attain the plant profitability target

- Plan for initiatives for continuous improvements to upgrade the quality and capacity of production process

- Work with Quality to reduce cost of poor quality (COPQ)

- Facilitate and support implementation of new systems and process improvements like ISO etc.

- Ensure adherence to quality standards by all, monitor the implementation of Quality Management Systems including documentation

Cost Reduction

- Work towards ensuring cost savings in variable costs through innovative ideas and optimum usage of raw materials, tools and consumables

- Work with the Technical Process, Plant Engineering and R&D teams to attain energy savings in the Production process

- Ensure efficient handling of the material and overall reduction in wastage

- Regularly liaison with SCM team for effective inventory planning

- Identify ways to reduce consumption of indirect material and implement the same at the plant

MIS and Reporting

- Track production expenditure to ensure compliance to the budget

- Ensure all production MIS is prepared and maintained by the respective Module Leaders as per the defined formats and timelines

- Ensure SAP is updated regularly and accurately by the team

Health and Safety

- Ensure safety measures are consistently and strictly followed in the plant and take initiatives to enhance acceptance of safety as a culture so as to achieve zero accident level

- Ensure all statutory, legal and procedural requirements on safety are consistently complied with

- Ensure all employees are adequately trained with respect to safety

- Conduct safety meetings of the department regularly to inculcate the importance of safety in the staff

- Report any incident to the Head Business Operations and Safety Head immediately

People Management

- Manage performance of the team and ensure that team is working in line with organizations value systems

- Ensure his team is adequately trained and proactively work at capability enhancement of team

- Conduct effective performance appraisals for the team and provide regular feedback

- Motivate, counsel and coach employees to ensure a conducive working environment

- Maintain good working relations with workmen and union members/operators to ensure a harmonious working environment at the plant