Plant Head - Defence Manufacturing

Plant Head

Responsibilities

Manufacturing Strategy & Execution:

Define and drive the plant’s long-term manufacturing strategy aligned with defence program goals, integrating sustainability (ESG), flexibility for multiple product variants (UAVs, ammunition, small arms), and readiness for future defence requirements.

Embed scalable, MIL-STD-compliant production systems that meet DGAQA quality mandates while supporting Make-in-India and indigenization objectives.

Lead digital transformation of the plant through adoption of Industry 4.0 technologies, smart manufacturing systems, and data-driven decision-making across functions.

Institutionalize strategic financial management for manufacturing, ensuring capital expenditure, cost per unit, and throughput are aligned with overall defence business goals.

Production Planning & Control:

Design and implement resilient, predictive, and agile planning systems leveraging AI/ML to manage complex defence production schedules under surge demands or emergency protocols.

Lead plant-wide integration of Sales & Operations Planning (S&OP), incorporating real-time demand changes, supply constraints, and priority shifts dictated by defence programs or MoD commitments.

Oversee optimization of line capacities across multiple SKUs and production variants, ensuring minimal downtime, zero resource bottlenecks, and highest production responsiveness.

Establish and monitor robust business continuity frameworks to safeguard delivery timelines in high-risk or disrupted scenarios (e.g., supplier failures, geopolitical risk, regulatory embargoes).

Quality Assurance & Compliance:

Champion a zero-defect manufacturing culture by implementing cutting-edge quality management systems (QMS) that go beyond AS9100 or MIL-Q-9858 compliance.

Guide the development and institutionalization of automated in-line inspection systems, SPC controls, and closed-loop feedback processes across production lines.

Interface directly with DGAQA, MoD, and internal quality agencies to align plant audit-readiness, certification timelines, and new product validation requirements.

Lead innovation in compliance systems by incorporating AI-enabled anomaly detection, predictive quality analytics, and paperless inspection traceability tools.

Operations Excellence:

Transform the plant into a benchmark "Lighthouse Factory" by driving lean digitalization, advanced automation, and operational transparency across all departments.

Launch and oversee enterprise-level TPM, Six Sigma, and VSM initiatives that yield tangible impact on OEE, material waste, energy use, and rework percentages.

Rapidly identify and resolve complex operational challenges (e.g., quality deviation in munitions, multi-product changeovers, or sudden capacity changes) through structured problem-solving and shopfloor engagement.

Foster a culture of relentless improvement and innovation, with cross-functional CI cells, monthly kaizen showcases, and formal ROI tracking for improvement projects.

Manufacturing Technology:

Drive plant-wide adoption of advanced and indigenous defence manufacturing technologies such as additive manufacturing, hybrid machining, robotics, and digital twins.

Establish internal Centres of Excellence (CoEs) to pilot, validate, and scale new manufacturing technologies in collaboration with DRDO, DPSUs, and academic partners.

Act as a strategic advisor on national defence technology roadmaps, contributing plant-level insights to industry forums and government-industry working groups.

Promote predictive maintenance and smart equipment integration to reduce unplanned downtimes and extend asset life for capital-intensive manufacturing lines.

Supply Chain Management:

Architect and manage an end-to-end defence-ready supply chain with built-in resilience, traceability, and multi-sourcing for mission-critical components.

Develop and enforce supplier qualification frameworks, long-term strategic partnerships (especially with MSMEs and DRDO-backed vendors), and logistics contingency protocols.

Lead indigenization initiatives through supplier development, import substitution programs, and local ecosystem integration in line with national defence procurement goals.

Implement crisis response mechanisms for supply disruptions including alternative routing, emergency contracting, and buffer stock strategies aligned to operational continuity needs.

Plant Safety & Security:

Build and oversee an intelligent plant safety management system that uses real-time monitoring, predictive risk analysis, and IoT-enabled alerts for proactive intervention.

Ensure compliance with all statutory, fire, chemical, and occupational health norms — especially for hazardous operations like munitions assembly, coating booths, or UAV battery handling.

Partner with internal security teams and external defence/security agencies to define and monitor physical access protocols, cyber-physical system security, and IP/data protection.

Establish benchmark safety performance through internal safety innovations, digital training programs, and root cause-based corrective action frameworks.

Leadership:

Lead the cultural and strategic transformation of the plant into a world-class, high-performance defence manufacturing site.

Build leadership depth and technical capabilities across all functions through a structured capability development roadmap and succession planning for key roles.

Set the tone for values-driven operations — embedding integrity, quality-first mindset, and accountability throughout the workforce.

Collaborate effectively with CXOs, BD, R&D, Finance, and HR to align plant performance with broader organizational goals and influence strategic decision-making at the enterprise level.

Key Stakeholders - Internal:

Head - Operations

Design Team

Quality Assurance Team

Maintenance Team

Manufacturing Team

Key Stakeholders - External:

DGAQA (Directorate General of Aeronautical Quality Assurance)

DRDO Labs & Project Directors

Private Defence OEM Partners

Local & National Regulatory Authorities

Qualifications

Educational Background:

B.Tech or M.Tech in Mechanical, Industrial, Manufacturing, or Production Engineering.

Certifications in Lean Six Sigma, TPM, Quality Management (e.g., AS9100 Lead Auditor), or Defence Production Systems preferred.

Work Experience:

18–25 years of progressive manufacturing leadership experience in defence, aerospace, or precision engineering industries.

Minimum 8–10 years in a plant leadership role with accountability for end-to-end manufacturing, quality, supply chain, and safety performance.

Industry Knowledge:

Thorough understanding of defence manufacturing protocols (MIL-STD, DGAQA, DRDO norms), advanced production technologies (CNC, robotics, additive manufacturing), and plant digitization (MES, Industry 4.0).

Proven expertise in leading operations excellence initiatives (TPM, Lean, Six Sigma), establishing compliant quality systems (AS9100, ISO 9001), and ensuring readiness for customer audits and factory acceptance tests (FAT).