Plant Head - CTC

Operations Head / Plant Head - CTC

Company: ALCU Industries Pvt Ltd (100% Subsidiary of M/s. Vidya Wires Ltd)

Position: Operations Head / Plant Head – CTC

Industry: Copper & Aluminium Wire & CTC Manufacturing

Location: Narsanda, Nadiad, Dist. Kheda, Gujarat

Reports To: Managing Director

Role Objective:

To provide strategic leadership, operational excellence, and overall management of the Continuous Transposed Conductors (CTC) manufacturing plants. The role focuses on driving productivity, efficiency, quality, cost optimization, compliance, and employee engagement to ensure smooth and profitable operations.

Key Responsibilities

1. Production & Operations

• Oversee the entire manufacturing process from incoming copper/ aluminium rods to finished CTC packages.
• Develop and execute production schedules to meet the stringent delivery timelines of transformer manufacturers (OEMs).
• Monitor key metrics such as OEE (Overall Equipment Effectiveness), throughput, and scrap rates.
• Manage bottlenecks specific to CTC manufacturing, including stranding, transposition, and paper taping lines.

2. Quality & Technical Compliance

• Ensure strict adherence to international standards (IEC, ASTM, IS) and customer-specific specifications regarding and dimensional accuracy.
• Lead root cause analysis (RCA) for critical defects such as insulation breakdown, burrs, and transposition errors.
• Implement Statistical Process Control (SPC) to maintain consistency in paper tension and conductor dimensions.

3. Maintenance & Engineering

• Oversee the preventive and predictive maintenance of high-speed CTC lines, paper lapping machines, and winding equipment.
• Lead the engineering team to minimize downtime and improve line speed without compromising insulation integrity.
• Manage CAPEX projects for capacity expansion, automation, and Industry 4.0 integration.

4. Supply Chain & Inventory

• Collaborate with procurement to ensure the availability of high-quality electrolytic copper/aluminium and high-grade electrical Kraft paper.
• Optimize raw material inventory (WIP) to reduce working capital while ensuring uninterrupted production.

5. Safety & Sustainability

• Champion a safety-first culture, specifically managing risks related to heavy machinery, high-voltage testing, and chemical handling (varnishes/solvents).
• Drive sustainability initiatives focusing on energy efficiency (copper melting and annealing consume significant power).

6. Team Leadership

• Lead, mentor, and structure a workforce comprising engineers, supervisors, and skilled technicians.
• Foster a culture of continuous improvement (Kaizen, TPM, 5S) and cross-functional collaboration.

Desired Candidate Profile:

Education: B Tech / B.E. in Mechanical, Electrical, Metallurgical, or Production Engineering. MBA (Operations) is preferred.

Experience: 15–20 years of experience in a manufacturing environment.

Preferably Minimum 8–10 years of experience specifically in the Continuous Transposed Conductors (CTC) manufacturing industry / the same product line.

• Technical Skills: Proficiency in ERP systems, Lean Six Sigma (Green / Black Belt preferred), and exposure to IATF 16949 or ISO 9001 systems.