Merino Group
Website:
merinolaminates.com
Job details:
To spearhead Dahej manufacturing operations and drive innovative strategic thinking, manage Company resources productively, direct the people development and deployment process, maintain quality & planned capacity utilization and oversee day to day operations. Drive overall operational efficiency and ensure optimal returns on investments. Plan and undertake initiatives for high machine uptime & lead process improvement initiatives. To contribute in planning for production, maintenance, dispatch and raw material. Drive cost savings through improvement projects and support new product development initiatives.
Process Excellence & Customer Centricity
Support Quality Control & Assurance
- Assure reliability and consistency of production; Ensure monitoring of manufacturing processes and output
- Participate in quality audits and customer inspections; Support resolution of all complaints and findings related to Quality issues in collaboration with quality assurance
Process & Engineering Improvements
- Ensure implementation and adherence to process improvement initiatives across the plant
- Oversee execution of OEE improvement initiatives in coordination with Engineering & Maintenance head
- Monitor consumption of general consumables, scrap production across products in plant; Develop and drive initiatives to reduce additional costs incurred in plant
Customer fulfilment
- Ensure maximum market servicing basis demand projections - Ensure OTIF; Drive production in line with outlined production plan
- Maintain high level of quality control in production to minimize defects
Strategy and planning
- Direct and lead planning of Capex and Opex for the plant (e.g., machinery, raw materials) in coordination with respective leads.
- Support development of plant manufacturing budget in coordination respective leads; Plan and allocate production budget and capacity in coordination with production planning department
- Oversee manpower planning, deployment and mobilization across production lines and shifts
- Oversee implementation of people strategy at plant.
- Prepare an annual manufacturing plan and policy guidelines to drive the performance of key result areas on production activities and continuous implementation monitoring.
- Implements, drives, and sustains key initiatives that support plant strategic goals.
Manufacturing Operations
- Plan and supervise manufacturing
- Support Production head in managing manufacturing operations
- Liaise with procurement head to ensure availability of required raw materials
- Ensure adherence to dispatch plan outlined in coordination with logistics manager
- Ensure regular maintenance of equipment as per outlined schedule across plant
- Ensure compliance with safety, quality and regulatory standards for the plant
- Liaise with engineering & maintenance head to ensure maintenance and availability of utilities e.g., electricity; Drive civil and mechanical projects at plant
- Oversee management of stores and spares at plant across products
- Oversee planning and implementation of maintenance schedules and shutdowns to enhance machine uptime, reduction in mean time between repetitive failures and contingency planning while ensuring production continuity
- Monitors the facility’s equipments needs and ensures that the technical team is working to keep the Company’s equipment and physical facility are properly maintained.
- Optimally make sure that manufacturing units improvise on the standard efficiencies in terms of Machine efficiencies, material yields, labor and overhead costs versus budget.
Performance monitoring and reporting
- Monitor performance and plant costs along key production metrics outlined by management; Drive correction of negative deviation vs budgeted if any
- Identify and highlight key deviations from plan; Suggest initiatives to resolve issues
- Perform operational audit in conjunction with process excellence head to determine manufacturing efficiency
- Work with plant finance controller to measure and track financial performance of plant
- Works to ensure that the facility’s OEE, OTIF, production targets; monitor target achievements are met through periodic reviews.
- Review daily, weekly and monthly production MIS reports to match actual performance vis-à-vis the targets and provide action steps to minimize variance
- Provides information to Corporate with SLA, including daily/weekly/monthly reporting requirements and other ad hoc information requests.
Procurement
- Monitor management and coordination of procurement related to plant including preparation of procurement budget for plant, evaluation of suppliers, contract negotiation, delivery and quality of raw materials
- Ensure adherence to inventory norms and minimize cost of inventory for all material types (RM, Consumables, etc.)
Logistics
- Oversee planning and coordination of timely movement of goods from plant including preparation of budget, managing inventory levels, tracking shipments, evaluation of vendors and contract negotiation
Strategic:
- Directs all aspects of the business operations, including purchasing, scheduling, manufacturing, warehousing, dispatch, quality assurance, customer service etc.
- Accountable for plant costs, throughput, utilization, manpower productivity & production costs
- Lead creation of the plant budget by consolidating inputs from various departments; ensure adherence to the approved budget
- Control of all operational aspects including cost & operations, production, quality, plant production improvement, health & safety and compliance.
- Ensure implementation of process improvements across products at plant to ensure improvement in key metrics
- Oversee the cost-effective management of all outsourced transportation service in consistence with budgeted levels of costs.
- Enforces all Company policies, including safety, production, quality, sales, human resources, customer service and accounting policies.
- Understands the technical aspects of the manufacturing facility so as to provide support to departmental personnel.
- Well versed with processes like IMS, QMS, ISO Audit & Compliance
- Constantly assesses the facility’s operational efficiencies and seeks out opportunities to improve processes in an economic manner.
- Ensure that all legal and statutory compliances for the plant are complied as per the required timelines
- Drive lean in every aspect of business practices and operations.
- Any assignment which needs to be done for addressing the Company needs/ objectives / emergencies / criticalities as directed by the Management time to time.
People: Staff + Manpower
- Guide and monitor performance of direct reports, providing timely feedbacks
- Support the identification of training and development to facilitate technical learning and growth of production staff and manpower
- Ensure adequate safety training for production staff and manpower
- Determine and communicate staffing needs to HR, interview candidates as necessary
- Manage and maintain labor and operating costs in accordance with budgets and strategic goals including cost due to rejections and rework etc.
- Ensure smooth coordination between production, quality control and maintenance functions in order to maintain parity/ clear understanding of targets/ expectations at all levels.
- Develop and nurture a dynamic and competent workforce through a robust performance driven culture.
Learning & Development
- Coach and develop staff to build high performing teams. Assigns stretch assignments to further train and enhance staff development.
- Promotes cross training to optimize workforce, ensures functional coverage, reduce labor costs, and supports succession planning.
- Oversees the hiring and training of facility personnel. Works with Human Resources to drive performance management of employees and seek out ways to motivate and develop employees.
Industrial Relations
- Manage the overall IR climate at the plant and ensure timely awareness and action for managing any labor issues
- Support interactions with unions, labor bodies in coordination with Plant HR + IR Head
- Oversee management of complaints and manage grievance redressal with the labor unions
- Build constructive relationships with all stakeholders both internally and externally (Govt. bodies, other industries bodies and external parties/ vendors.)
Liaison
- Coordinate with external stakeholders e.g., regional administrative bodies, industry bodies, and labor unions; Ensure prompt issue resolution
- Meeting all statutory, regulatory & admin at plant site
- Oversee environmental health and safety - Ensure compliance with health and safety standards and industry codes
- Oversee and extend full support for compliance to all statutory government regulations.
Employee health & safety
- Oversees all employee management, while being a champion for safety at the facility.
- Support development of employee health and safety procedures and policies
- Ensure regular safety inspections, and training of employees on safety procedures
- Drive reporting and investigation of accidents and incidents pertaining to employee safety and health
- Ensure compliance with employee health and safety standards, and regulations
- Drive Kaizen and other improvement initiatives.
- Monitor and ensure strict adherence to all safety & environment norms and drive safety as a culture in the plant Digital First
- Employ digital tools to ensure accurate scheduling and tracking of production operations
- Leverage digital tools to maintain quality standards in production and manufacturing
- Develop and report monthly performance reports on production, including updated forecasts for the rest of the year to support production and logistics planning
Key Performance Indicators
Financial Performance
- Plant operating expenditure vs budgeted
- LPL production expenditure vs budgeted
- Plant Capex RoI
- Fixed expenses vs Budgeted
Operational Performance
- Quality (customer returns and complaints)
- OTIF
- Overall equipment effectiveness
- Throughput
- Manufacturing process cycle time
- Capacity utilization (%)
- Worker productivity - Output per plant worker FTE
- Inventory days (# of days inventory held in warehouse)
- Scrap rate (% of raw material lost in production)
Compliance
- # Reported compliance (Safety, Quality, Regulatory) violations
- Cost of compliance violations
- Average compliance violations closure time
- Industrial Relations - # of grievances reported, average complaint closure time
Desired Position Qualification
- 20+ years of total working experience, ideally in production and manufacturing in Tyre/Rubber/Polymer/Chemicals, Consumer electronics /Electrical ( industrial /Automotive Components Parts
- Deep understanding of manufacturing and operations, with ability to make decisions
- Strong leadership, management and interpersonal skills
- Strong analytical skills
- Technical certification required, if any or soft skills needed to be mentioned here.
Desired Education Qualification
- Bachelor’s in Engineering (Mechanical/ Electrical/ Production/Chemical) preferably MTech.
- MBA/ degree in business administration will be an added advantage.
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