Plant Operations Manager

Position Objective:

To oversee the entire housing wire manufacturing unit. This role is responsible for driving daily production targets, optimizing operational costs, and maintaining strict compliance with national quality benchmarks like BIS/ISI standards. The ideal candidate will blend strategic leadership with strong floor-level technical expertise to maximize capacity utilization and integrate a seamless supply chain.

1. Operations & Production Management

- Daily Oversight:
Direct and supervise all daily manufacturing operations, including wire drawing, extrusion, annealing, coiling, and packaging.
- Production Planning:
Formulate and execute robust Production Planning and Control (PPC) schedules to meet market demands and achieve optimal capacity utilization.
- Maintenance Coordination:
Oversee preventative and breakdown maintenance of manufacturing machinery (e.g., high-speed extruders, bunchers, drawing machines) to minimize downtime.

2. Quality Assurance & Compliance

- Regulatory Compliance:
Maintain full ownership of BIS (Bureau of Indian Standards) and ISI marking processes, ensuring all housing wires meet rigorous national safety and quality benchmarks.
- Standard Operating Procedures (SOPs):
Implement and enforce strict QA/QC protocols across the production line to guarantee zero-defect output.
- Safety & Audits:
Ensure 100% compliance with factory safety norms, environmental regulations, and periodic statutory audits.

3. Cost Optimization & Resource Management

- Material Management:
Optimize the consumption of critical raw materials like Copper, Aluminum, and PVC/XLPE compounds.
- Wastage Reduction:
Implement tracking systems to drastically minimize scrap, burn-off, and material variance during extrusion and drawing stages.
- Budgetary Control:
Manage plant operational expenditures (OPEX) and drive cost-saving initiatives without compromising product integrity.

4. Workforce & Team Leadership

- Labor Relations:
Foster a productive, safe, and harmonious working environment; effectively handle labor relations and grievance redressals on the shop floor.
- Team Development:
Manage, mentor, and evaluate floor supervisors, engineering teams, and maintenance staff to upgrade plant-wide skill levels.

5.Technical & Functional Competencies

- Process Knowledge:
Deep technical understanding of wire drawing, bunching, compounding, and PVC extrusion processes specifically geared toward building/housing wires (FR, FRLS, ZHFR variants).
- Continuous Improvement:
Proven track record of deploying Lean Manufacturing, Six Sigma, 5S, and Kaizen frameworks to improve floor efficiency.
- Inventory & ERP:
Familiarity with inventory management tools and modern ERP systems (like SAP or Oracle) for supply chain tracking.

Experience & Qualification

- 10–15 years of total experience in wire and cable manufacturing, with a mandatory 3–5 years of experience independently heading a housing wire production line.
- Bachelor’s Degree (B.E./B.Tech) in Mechanical, Electrical, or Production Engineering. A diploma in Plastic/Polymer technology is a strong plus.

Performance Indicators (KPIs)

A candidate's success in this role will be measured by:

- Overall Equipment Effectiveness (OEE) and overall plant capacity utilization.
- Scrap/Wastage percentage against established industry baselines.
- Zero non-compliance findings during external BIS/ISI certification audits.
- On-time delivery performance to the warehouse or distribution chain.