Head Operations

Purpose of the Job

The role of Head Operations (Plant Head) is to develop and execute effective operational strategies for manufacturing functions helping organization create customer value while ensuring overall cost competitiveness. The incumbent will be responsible for managing production operations, maintenance & process excellence initiatives in Khyber cement. In addition, he will also lead capacity expansion plans, process automation & technology up gradation initiatives, maintenance systems & processes and environment, health & safety agenda for the business.

Key Responsibilities

Plant Operations

• Decide long-term operational plans for the department in alignment with key future priorities of the organization such as investments on new technology, manpower optimization in various departments, focus on product quality etc.
• Introduce and initiate new practices for better operations and processes, for example, stores spares meeting for inventory management and weighment of hired vehicles to ensure adherence etc.
• Ensure manufacturing cost for the organization are managed within the budgeted limits.
• Carry out review and analysis of daily process log sheet and other key production parameters to identify deviations and prepare mitigation plans for corrective and preventive action.
• Control sectional budget for maintenance spares, power and fuel to drive improvements in key cost parameters.
• Review proposals for creative and innovative ideas in the plant and guide on best possible course, for example, undertaking best practices in the plant and initiating new practices to improve quality of life of employees.
• Carry out daily interactions, predominantly with internal stakeholders of all departments, including Mechanical, E&I, Process, Packing Plant etc.; Undertake interactions with critical external stakeholders such as unions, villagers, politicians & bureaucrats.
• Convince internal user departments for change in processes such as convincing Chiefs to change processes for productivity, cost & equipment reliability improvements.
• Monitor breakdowns and failures at plants and implement initiatives for preventive and utility maintenance (AMC and spares management).

Projects

• Ensure execution of any capacity expansion plans through acquisition of new equipment, augmenting plant capacity, venturing in Greenfield projects etc.
• Approve procurement of all major capital expenditure expenses for operations in coordination with the finance & procurement functions.
• Focus on enhancing manufacturing efficiencies and improving process controls by leveraging initiatives focused towards technology up gradation, process automation etc.
• Drive a culture of innovation and continuous improvement across the organization through planned initiatives.

Employee Engagement & Safety

• Ensure nil lost time accidents through robust implementation of safety guidelines.
• Drive a culture promoting focus on environment, health and safety across the organization.
• Strengthen employee engagement levels in operations team building a positive working climate for all team members.

Operational Excellence

• Adherence to process performance, production, power and fuel data.
• Achievement of production targets at desired costs.
• Identification of inefficiencies and problems, review of proposals and up gradation of plant & equipment.
• Cost optimization for Process (manpower, store spares, inventory, new projects and new practices).
• Improve processes, systems and working methods in the plant in order to deliver better outcomes in terms of productivity and cost metrics, for example, taking initiatives such as equipment modification to drive cost improvements.
• Proactively drive improvements in the plant processes, techniques and methodologies by constant analysis of plant performance metrics and devising ways of improvement.
• Present business case to management and convince for implementation of innovative initiatives.
• Implement continuous improvement initiatives in plants to maintain required Original Equipment Efficiency (OEE) and Line Efficiency.
• Ensure standardization of manufacturing processes and implement action plan across plants.

Quality Control

• Lead and guide all quality related aspects at the plant site by implementing quality management systems, quality plans and controls to achieve plant objectives.
• Ensure the quality of products and their compliance with the standardized and market requirements.
• Ensure completion of quality control tests and inspection tasks for raw materials (e.g. chemical analysis of packing bags), in-process and finished products. Overall control of Raw Mix designing, finish product mix design etc.
• In charge for the achievement of key performance indicators in the field of product quality and quality systems related agreed targets for the overall plants performance.
• Define and set quality targets for the production department.
• Maintain relationship with external stakeholders.
• Carry out different trials related to Research & Development for development of new products related to cement & concrete.
• Recommend and implement quality control methodologies in cooperation with the production department.
• Coordinate and carry out product quality tests and recommend measures for its improvement.
• Plan cost and capital budget for the department; adhering to revenue budget. Execute various capital budget jobs in the department with strict adherence to cost & schedule.
• Ensuring optimal quality of raw materials, fuels and products.

Regulatory Affairs

• Develops and drives systems and processes ensuring compliance to product quality standards such BIS, NCBM etc.
• Ensure successful completion of all statutory and product safety audits with nil observations.
• Develop and drive training on quality management system ( IMS) for the continuous improvement of all quality related processes for all relevant role holders.

Process Excellence & Equipment Calibrations

• Develop and drive process excellence initiatives such as six sigma interventions, total productivity maintenance etc. to enable superior cost efficiencies and quality levels across the organization.
• Standards used to calibrate the instruments are regularly validated and recalibrated.
• Maintenance of a set of calibration standards that are traceable to national standards laboratories, and their regular recalibration.
• Calibration of various laboratory equipment by internal as well as external agencies to ensure effectiveness of test result.

Education

• B. tech - Mechanical/ Diploma from Tier 1 / Tier 2 College with 25-30 years of experience

Experience

• Typical role requires an experience of ~ 25 years of professional experience in Cement or related plants with exposure of managing large plants
• Role requires deep understanding of technical, financial and operational aspects of production and maintenance and ideally of commissioning of new projects as well
• Role requires exposure to handle multi-faceted problems while leading a plant

Personality & Culture Fit

• Integrity
• Attention to detail
• Collaborative
• Analytical
• Sound judgement
• Curious

Competencies

Behavioral Competencies

• People Management
• Influencing Skills
• Strategic Thinking
• Change Management
• Problem Solving
• Stakeholder Management
• Decision Making

Technical Competencies

• Product Knowledge
• Production Management Techniques
• Project Management
• Quality Management Systems
• Safety and Sustainability Protocols