Factory Head

Role & responsibilities

1. Production & Operations

• Lead the overall operations of the ferro alloys plant (submerged arc furnace, power plant, raw material handling, etc.).
• Plan, monitor, and achieve monthly/annual production targets.
• Optimize power consumption per ton of alloy produced (a critical KPI in ferro alloys).
• Ensure uninterrupted coordination between furnace, power plant, and raw material availability.
• Implement lean manufacturing, TPM, and continuous improvement practices.

2. Quality & Process Control

• Maintain quality parameters as per customer specifications and industry standards.
• Monitor furnace chemistry, raw material mix, slag handling, and tapping practices.
• Oversee laboratory and metallurgical testing, ensuring strict QC protocols.
• Minimize off-grade production and yield losses.

3. Maintenance & Reliability

• Ensure preventive and predictive maintenance of furnace, transformers, electrodes, power plant, and auxiliaries.
• Reduce breakdown frequency, improve equipment reliability, and ensure availability of critical spares.
• Implement root cause analysis (RCA) for failures and corrective actions.

4. Safety, Health & Environment (SHE)

• Enforce strict safety standards (PPE, furnace safety, fire prevention, electrical safety).
• Ensure compliance with pollution control board (PCB) norms emissions, slag disposal, water treatment, noise levels.
• Promote a strong safety culture, conduct regular training and audits.

5. Cost & Efficiency Management

• Monitor and control production costs (power, electrodes, reductants, raw materials, consumables).
• Drive efficiency improvements power consumption, raw material yield, manpower productivity.
• Track KPIs such as OEE (Overall Equipment Effectiveness), specific power consumption, cost/ton.

6. People & Workforce Management

• Lead, motivate, and manage cross-functional teams (Production, Maintenance, QC, HR, Admin, Safety).
• Develop workforce skills, with focus on local employment and capacity building.
• Maintain discipline, resolve conflicts, and ensure smooth labor relations.

7. Liaison & External Coordination (Liaison Efficiency)

• Act as the key interface with government authorities (Factory Inspector, State Pollution Control Board, Labor Department, Mining Department, Electrical Inspector, etc.).
• Ensure all statutory compliances: Factory Act, Electricity Act, Environmental clearances, Mines & Minerals regulations, labor laws.
• Liaise with power suppliers (State Electricity Boards / captive power coordination) for uninterrupted power supply and tariff-related matters.
• Coordinate with local administration, community leaders, and law & order authorities to ensure smooth operations.
• Handle CSR and local community relations for goodwill and long-term sustainability.

8. Planning, Budgeting & Reporting

• Prepare annual production, maintenance, and cost budgets.
• Review performance periodically and report to senior management.
• Suggest capex for plant upgrades, expansions, and new technology adoption.

9. Strategic Growth & Innovation

• Drive technology upgrades for better furnace efficiency and product quality.
• Explore opportunities for product diversification (different ferro alloys, export markets).
• Lead sustainability initiatives waste heat recovery, renewable energy integration, zero-liquid discharge systems.

Preferred candidate profile

years of experience in Ferro Alloys / Steel / Metals & Minerals industry, with at least 5+ years in a leadership role as Plant/Factory Head or Production Head.

1. Hands-on experience in production planning, furnace operations, raw material management, and power cost optimization.

2. Strong background in statutory compliance, liaison with government bodies, and handling audits

3. In-depth knowledge of ferro alloys manufacturing (ferro-silicon, ferro-manganese, silico-manganese, etc.).

4. Strong understanding of power-intensive operations and cost reduction techniques.

5. Familiarity with quality management systems (ISO, BIS) and HSE standards.

6. Strong leadership with ability to manage cross-functional teams (Production, Maintenance, QC, HR, Safety, Power Plant)

7. Proven ability to mentor, motivate, and build high-performance teams.

8. Strategic thinking with focus on efficiency, profitability, and long-term growth.

9. Demonstrated efficiency in liaison with government agencies (Pollution Control Board, Factory Inspector, Mining & Power authorities, Labor Department, etc.)

10. Ability to represent the company with regulatory bodies, customers, suppliers, and local community leaders.

11. Strong decision-making under pressure.

Perks & Benefits

Fully furnished housing facility near the plant/estate, maintained by the company.