Plant Head _Steel Processing _Auto Ancillary

Plant Head / Factory Head Steel Processing Centre

Department: Plant Operations
Reports To: COO / Managing Director
Location: Chhatrapati Sambhaji Nagar, Maharashtra
Experience: 15+ Years
Industry: Steel Processing / Auto Ancillary / Sheet Metal / Automotive

About the Role

We are looking for an experienced Plant Head / Factory Head to lead end-to-end plant operations of a Steel Processing Centre engaged in coil slitting, CTL/CTS, shearing, blanking, auto blanking and shaped sheet-metal components for Tier-1 automotive customers and steel industry customers.

The role will be responsible for Production, Quality, Maintenance, Supply Chain, Cost, Safety, People, Customer Management and overall Plant Performance.

Key Responsibilities

Plant Operations & Production

• Lead complete plant operations covering Slitting, CTL/CTS, Shearing, Blanking, Auto Blanking and shaped-component operations.
• Drive production planning, capacity utilisation, machine utilisation and schedule adherence.
• Improve OEE, productivity, throughput, yield and machine uptime.
• Ensure timely delivery to Tier-1 automotive customers and steel mill customers.

Cost, Budget & P&L

• Prepare and manage annual OPEX and CAPEX budgets for the plant.
• Monitor cost per ton, conversion cost, energy cost, manpower cost and maintenance cost.
• Drive steel yield/recovery, scrap reduction and cost-reduction initiatives.
• Lead Kaizen, VA/VE and continuous improvement projects.
• Monitor plant profitability, working capital and inventory levels.

Quality Management

• Ensure compliance with IATF 16949 / ISO requirements and customer-specific requirements.
• Drive APQP, PPAP, FMEA, SPC, 8D and CAPA activities.
• Monitor Customer PPM, internal rejection, first-pass yield and customer complaints.
• Ensure proper first-off inspection, calibration and die/tool qualification.

Supply Chain & Customer Management

• Manage raw material planning and coordination with steel mills for HR/CR coils.
• Ensure optimum raw material, WIP and finished goods inventory.
• Drive OTIF and customer delivery performance.
• Handle customer escalations and support new product/customer development.
• Manage suppliers for tooling, dies, spares and outsourced processes.

Maintenance & Asset Management

• Ensure effective Preventive, Predictive and Breakdown Maintenance.
• Drive TPM, MTBF, MTTR and planned-vs-breakdown maintenance improvement.
• Manage maintenance of slitting lines, blanking presses, shearing equipment and material handling systems.
• Ensure effective die, tooling and critical spare management.

Safety & Compliance

• Ensure compliance with applicable Factories Act, EHS, fire safety, pollution control and statutory requirements.
• Drive plant safety through LTIFR, near-miss reporting, safety audits and corrective actions.
• Build a strong safety culture across all plant functions.

People & Leadership

• Lead and develop the plant leadership team across Production, Quality, Maintenance, Stores/Logistics, HR and Finance.
• Drive manpower planning, workforce productivity and skill development.
• Establish clear KRA/KPI systems for functional heads and plant teams.

KRA / KPI & Strategy Deployment

• Translate business objectives into plant-level KRAs and KPIs.

• Deploy Hoshin Kanri / X-Matrix and SMART objectives across functions.

• Monitor key plant KPIs covering:

• Safety: LTIFR, near-miss closure, safety audit score

• Quality: Customer PPM, rejection, IATF performance, PPAP

• Delivery: OTIF, schedule adherence

• Cost: Cost/ton, conversion cost, energy cost, yield and scrap

• Productivity: OEE, tons/man-hour, uptime, changeover time

• People: Attrition, training, skill-matrix coverage

• Growth: Capacity utilisation, new business and new-part approvals

• Conduct daily Gemba/shift reviews, weekly KPI reviews and monthly plant performance reviews.

• Drive PDCA and corrective action closure for off-track KPIs.

Education

BE/B.Tech Mechanical / Production / Industrial Engineering / Metallurgy
ME/M.Tech or MBA/PGDM Operations / Supply Chain will be an added advantage.

Experience

15+ years of relevant experience, preferably in:

• Steel Processing Centre / SPC
• Steel Coil Processing
• Auto Ancillary / Automotive
• Sheet Metal Manufacturing
• Coil Slitting
• CTL / CTS
• Blanking / Auto Blanking
• Shearing
• Tier-1 Automotive Supplier

Key Skills

Plant Head, Factory Head, Plant Operations, Manufacturing Operations, Steel Processing, Steel Coil Processing, Slitting, CTL, CTS, Shearing, Blanking, Auto Blanking, Sheet Metal, OEE, TPM, Lean Manufacturing, Kaizen, IATF 16949, APQP, PPAP, FMEA, SPC, 8D, CAPA, CAPEX, OPEX, P&L, Cost Control, Yield Improvement, Scrap Reduction, OTIF, Supply Chain, Preventive Maintenance, Tooling Management, Vendor Management, KRA, KPI, Hoshin Kanri, X-Matrix, PDCA, EHS, Team Management.

Preferred Candidate Profile

Candidates with strong experience in Steel Processing / Coil Processing / Slitting / Blanking / CTL / CTS, managing automotive Tier-1 customers, and handling complete plant operations with P&L, CAPEX, OPEX, quality, delivery, safety and people responsibility will be preferred.

If you are interested, please share your updated CV at [email protected]