Position Overview:

Department / Division: Operations

Country: India

Site: Oragadam, Chennai

Reports To (N+1): Managing Director

Reports To (N+2): SVP Asia

Internal Relations: Production / Quality / Program Management / Engineering / Sales / SCM / HR / Finance

External Relations: Customers / Suppliers / Government Authorities

Job Dimensions:

The Plant Manager will lead end-to-end Operations at the Chennai facility, covering production, quality, maintenance, supply chain, and people management.

Purpose of the Role:

The Plant Manager will lead end-to-end operations at the Oragadam facility, covering production, quality, maintenance, supply chain, and people management. The role demands strong technical expertise in automotive manufacturing processes, operational excellence, and leadership capability to drive productivity, efficiency, and profitability.

Key Activities & Responsibilities:

Plant Leadership & Strategy:

- Head overall plant operations: Production, Quality, Maintenance, PPC, Supply Chain, Tooling, EHS, and HR coordination.

- Deploy manufacturing strategy aligned with business goals and customer demand.

- Lead new product introduction, line setup, capacity expansion, and technology upgrades.

- Build leadership bench strength, succession planning, and performance culture.

- Effectively manage all plant operations rituals such as Safety walk, GEMBA, QRQC, KPI review, shift management, document controls, and quality systems.

Production & Operational Excellence:

- Achieve all KPI objectives (Safety, Quality, Delivery, Cost, Labour efficiency).

- Drive improvements in OEE, cycle time, changeover reduction, layout optimization, and manpower productivity.

- Ensure production runs against firm work orders; monitor order completion and delivery commitments.

- Implement FIFO for material usage and ensure uninterrupted production flow.

- Conduct daily work management meetings and gap analysis for production shortfalls.

Maintenance & Cost Control:

- Hands-on experience in production and utility maintenance.

- Control breakdown hours, power cost, fuel cost, and maintenance expenses as per AOP targets.

- Implement TPM, preventive maintenance, spares planning, and asset lifecycle management.

- Analyze costs and drive reduction initiatives (scrap, energy, automation, VA/VE).

Quality & Customer Management:

- Ownership of plant quality metrics: PPM, FPY, COPQ, customer complaints.

- Lead APQP, PPAP, FMEA, control plans, MSA, SPC, and product launches.

- Ensure compliance with ISO standards, IATF 16949, and customer-specific requirements.

- Conduct root cause analysis for defects and implement corrective measures.

- Act as senior interface with OEMs and Tier-1 customers during audits and reviews.

Product Line Oversight:

- Anti-Vibration Systems (AVS): Oversee design, production, and testing of vibration control components; ensure NVH performance, durability, and compliance with OEM standards.

- Body Sealing Systems (BDS): Manage extrusion, moulding, and assembly of sealing systems; control dimensional accuracy, compression set, water leakage prevention, and long-term reliability.

- Precision Sealing Systems (PSS): Lead production of precision sealing for engines, transmissions, and critical automotive systems; ensure tight tolerance control, thermal/chemical resistance, and zero-leak performance.

People Leadership & Industrial Relations:

- Lead and develop departmental heads and frontline leadership.

- Build structured training systems and technical capability pipelines.

- Ensure stable industrial relations, statutory compliance, and ethical labor practices.

- Drive engagement, discipline, safety culture, and performance management systems.

Continuous Improvement & Digitalization:

- Champion Lean, TPM, Six Sigma, Kaizen, 5S, and daily management systems.

- Lead automation, traceability, MES, and smart factory initiatives.

- Establish strong MIS, visual management, and review cadence.

Safety, Health & Environment:

- Ensure world-class safety standards and a zero-accident culture.

- Lead ISO 14001, ISO 45001, statutory audits, and sustainability programs.

- Oversee risk assessments, machine safety, electrical safety, and environmental compliance.

Context and Environment:

The position is based in Chennai.

Required Profile:

Education:

- B.E / B.Tech in Mechanical, Production, Automobile, or Industrial Engineering.

Experience:

- 20- 22 years in automotive manufacturing, with 510 years in a Plant Head / Operations Head role.

- Mandatory Tier-1 automotive exposure.

Competencies:

- Strong OEM / Tier-1 customer handling.

- Expertise in APQP, PPAP, FMEA, SPC, and MSA.

- Financial acumen and crisis management.

- Proven ability to scale plants.