Operation Head / Plant Head

JOB DESCRIPTION – HEAD OF MANUFACTURINGCompany Name: Magnaplast Technologies (India) Pvt. Ltd.

• 1. Position DetailsDesignation: Head – Manufacturing
• Department: Manufacturing & Operations
• Reporting To: Managing Director / Director
• Location: Pune, Maharashtra
• Experience: 20+ Years (Mandatory)
• Qualification: B.E. / B.Tech in Mechanical, Production, Polymer or Industrial Engineering
• Preferred Qualification: MBA / PGDM in Operations Management
• Industry: Manufacturing / Engineering / Automotive / Polymer / Industrial Products

2. Job ObjectiveTo lead and manage the company's complete manufacturing operations with responsibility for production, productivity, capacity utilization, manufacturing costs, quality, delivery, maintenance, tooling, manpower efficiency and continuous improvement.

The role requires a business-oriented manufacturing leader capable of improving operational efficiency, controlling manufacturing costs, achieving production targets and improving overall manufacturing profitability.

• 3. Key ResponsibilitiesA. Manufacturing & Production OperationsManage overall manufacturing operations, production lines, shifts and shop-floor activities.
• Prepare and execute daily, weekly and monthly production plans.
• Achieve a minimum of 95% of approved production targets.
• Optimize machine utilization, manpower deployment and material consumption.
• Identify and eliminate production bottlenecks.
• Ensure timely production against customer requirements.
• Implement 5S, shop-floor discipline, safety and operational standards.
• B. Manufacturing Cost Control & P&LPrepare and review monthly Manufacturing Profit & Loss (P&L) reports.
• Monitor actual manufacturing costs against budgets and standard costs.
• Control raw material consumption, labour, power, maintenance, tooling, consumables and overhead costs.
• Analyse product-wise manufacturing costs and contribution.
• Reduce scrap, rejection, rework and unnecessary expenses.
• Coordinate with Accounts and Finance for cost analysis and profitability improvement.
• Develop and implement annual cost-reduction plans.
• C. Production Planning & Capacity ManagementPrepare production and capacity plans based on customer demand and sales forecasts.
• Monitor machine-wise capacity and utilization.
• Identify capacity constraints and improve bottleneck performance.
• Plan manpower, shifts, outsourcing and additional capacity as required.
• Evaluate existing capacity before recommending capital investment.
• Support management in business expansion and long-term manufacturing planning.
• D. Productivity & Continuous ImprovementDrive Lean Manufacturing, TPM, OEE, Kaizen and process optimization.
• Improve machine output and employee productivity.
• Reduce cycle time, changeover time and production losses.
• Improve plant layout and material flow.
• Identify automation and process-improvement opportunities.
• Track cost savings and productivity improvement projects.
• E. Quality, Scrap & Rejection ControlCoordinate with the Quality Department to resolve manufacturing quality issues.
• Analyse root causes of rejection, rework and process defects.
• Implement corrective and preventive actions.
• Improve First Pass Yield (FPY) and process consistency.
• Monitor manufacturing-related customer complaints.
• Establish effective process controls and reduce scrap generation.
• F. Maintenance & Tooling ManagementEnsure effective preventive and predictive maintenance of machines.
• Monitor machine breakdowns, downtime and equipment availability.
• Identify recurring breakdowns and implement permanent corrective actions.
• Ensure availability of critical spare parts.
• Monitor tooling performance, tool life and maintenance schedules.
• Coordinate tool development, modification and improvement activities.
• Minimize machine and tooling-related production losses.
• G. New Product & Process DevelopmentCoordinate with R&D, Sales, Quality, Purchase and Tool Room teams for new products.
• Evaluate manufacturing feasibility, machine requirements and tooling requirements.
• Estimate cycle time and manufacturing costs.
• Plan trials, process validation and production readiness.
• Ensure smooth transfer of new products from development to mass production.
• H. Manpower & Team ManagementLead the manufacturing organization and develop departmental leadership.
• Establish responsibilities, performance targets and KPIs for teams.
• Optimize manpower utilization and control overtime.
• Develop multi-skilled operators and supervisors.
• Identify training needs and improve employee capabilities.
• Conduct daily, weekly and monthly performance reviews.
• Promote accountability, discipline, teamwork and a safety-oriented culture.
• I. CAPEX & Investment ManagementIdentify requirements for new machines, automation and technology upgrades.
• Prepare CAPEX proposals with technical and financial justification.
• Evaluate ROI, payback period and expected productivity benefits.
• Monitor project implementation, budgets and commissioning.
• Review the actual benefits achieved after investment.
• J. ERP, MIS & Management ReportingEnsure accurate production and manufacturing data in ERP/MRP systems.
• Prepare and review daily production, downtime, rejection and manpower reports.
• Monitor weekly production performance, capacity utilization, OEE and cost variances.
• Prepare monthly management reports covering:
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• Manufacturing P&L and product-wise manufacturing cost
• Production achievement and capacity utilization
• Scrap, rejection and rework
• Labour productivity and overtime
• Machine downtime and maintenance cost
• Energy cost and cost-reduction initiatives
• CAPEX performance and corrective action plans
• K. Strategic & Management ResponsibilitiesParticipate in manufacturing strategy and annual budget planning.
• Support capacity expansion and business growth initiatives.
• Evaluate make-versus-buy and outsourcing decisions.
• Recommend improvements in plant layout, automation and manufacturing technology.
• Develop a long-term manufacturing roadmap.
• Report operational performance, major risks and improvement plans directly to the Managing Director / Director.

4. Key Performance Indicators (KPIs)The performance of the Manufacturing Head will be measured through:

1. Production Plan Achievement – Minimum 95%.
2. Capacity and Machine Utilization.
3. Overall Equipment Effectiveness (OEE).
4. Manufacturing Cost per Unit.
5. Manufacturing P&L vs. Budget.
6. Raw Material Yield and Consumption.
7. Scrap, Rejection and Rework Reduction.
8. First Pass Yield and Customer Complaints.
9. Machine Availability and Breakdown Hours.
10. Labour Productivity and Overtime Control.
11. Energy Cost per Unit.
12. On-time Production and Delivery.
13. Tooling-related Downtime.
14. CAPEX ROI and Payback.
15. New Product Industrialization Performance.
16. Annual Cost-Saving Target Achievement.
17. Team and Department KPI Achievement.

5. Required Experience & SkillsMandatory Experience

• Minimum 20 years of manufacturing experience.
• At least 5–10 years in a senior leadership role such as Plant Head, Manufacturing Head, Operations Head or Factory Head.
• Proven experience managing complete manufacturing operations and large teams.
• Strong understanding of manufacturing costing, P&L analysis and cost control.
• Experience in capacity planning, CAPEX and productivity improvement.
• Strong shop-floor management and business decision-making capabilities.

Preferred Industry Experience

• Automotive and Engineering Manufacturing.
• Polymer, Magnet and Industrial Products.
• Injection Moulding, Extrusion or other manufacturing processes.
• Multiple-shift manufacturing operations.

Technical Skills

• Production and Operations Management.
• Manufacturing Costing and P&L Analysis.
• Production and Capacity Planning.
• Lean Manufacturing, TPM, OEE and Kaizen.
• Quality and Process Control.
• Maintenance and Tooling Management.
• CAPEX Evaluation and ROI.
• ERP/MRP, MIS and Inventory Management.
• Safety, 5S and continuous improvement.

Leadership Skills

• Strong ownership and accountability.
• Analytical thinking and problem-solving.
• Cost-conscious and business-oriented approach.
• Team leadership and decision-making.
• Effective communication and negotiation.
• Ability to work directly with senior management.
• Integrity, discipline and performance orientation.

6. Expected OutcomesThe successful candidate is expected to achieve:

• Higher production and capacity utilization.
• Lower manufacturing cost per unit.
• Reduced scrap, rejection and rework.
• Improved machine availability and OEE.
• Higher manpower productivity.
• Better quality and on-time delivery.
• Effective CAPEX utilization and measurable cost savings.
• Improved manufacturing profitability and operational control.

7. Overall AccountabilityThe Head – Manufacturing will have overall responsibility for Production, Quality, Cost, Productivity, Capacity, Maintenance, Tooling, Manpower, Manufacturing P&L and Continuous Improvement, with direct reporting to the Managing Director / Director.

Primary Objective: To achieve profitable, efficient, reliable and sustainable manufacturing operations.