Bhatia Alloy Forgings Private Limited
Website:
bhatiaalloy.com
Job details:
Company Description
Bhatia Alloy Forgings Private Limited, established in 1996, is a leading provider of integrated solutions for manufacturing aluminum and other lightweight materials. Committed to sustainability, the company focuses on creating high-strength, lightweight, and recyclable products to improve efficiency and safety while reducing environmental impact. With state-of-the-art facilities and advanced processes such as hot and cold forging, heat treatment,Machining, surface finishing, and testing, Bhatia Alloy caters to the evolving needs of OEMs. The company's mission is to enhance vehicle safety, comfort, and environmental compliance. Headquartered in India, they are driven by innovation and sustainability to help clients achieve scalable business growth.
Position Title: Plant Head- Aluminium Forging Plant 1
Department: Operations
Reports to: CEO
Location: Plant- 1 (Sector-24, Faridabad)
Qualification & Experience: Dip./ BE. / B.Tech. Mechanical
Experience: 15 Yrs.+
Grade: D1
Role SummaryThe Plant Head – Aluminium Forging is accountable for the entire forging plant’s operational and business performance. The role is responsible for achieving production and sales-linked delivery plans with optimum cost, high quality, strong safety, asset reliability, and disciplined cross-functional execution. The Plant Head must act as the integrator between PPC, Production, Tool Room, Process Engineering, Quality, Maintenance, HR, Purchase, Stores, Finance/Accounts, and NPD to ensure that operational goals are met without compromising margins, compliance, or long-term capability.
Key AccountabilitiesA. Business Plan to Production Execution- Convert customer demand, rolling forecast, and sales plan into executable production plans.
- Ensure capacity loading is realistic and aligned with machine, die, manpower, maintenance, and material constraints.
- Drive daily/weekly/monthly production reviews to ensure committed volumes are delivered.
- Ensure no line stoppage or internal disruption due to poor coordination.
B. DOTIF and Customer Delivery Reliability- Own plant contribution to OTIF / OTD performance.
- Coordinate PPC, Stores, Production, Quality, and Dispatch to ensure internal and external commitments are met.
- Anticipate bottlenecks early and trigger corrective action before delivery risk materializes.
- Ensure plan adherence without hidden WIP distortion or last-minute firefighting.
Your current JD already makes OTIF a direct responsibility and positions the Plant Head as accountable for aligning planning, inventory, dispatch, and bottleneck removal.
JD - Plant Head-Aluminium Forgi…
C. Cost and Productivity Ownership- Own plant conversion cost and operating efficiency.
- Monitor and improve:
- labour productivity
- output per press / per shift
- energy consumption
- rework and rejection loss
- overtime
- indirect cost leakage
- consumable usage
- die-related productivity loss
- machine downtime loss
- Work with Accounts and Finance to track actual vs budget by cost center.
- Drive action on adverse variances, not just report them.
D. Production and Process Control- Ensure process adherence across billet heating, forging, trimming, deburring, in-process handling, and related operations.
- Ensure standard cycle, load, setup, and process parameters are followed.
- Challenge process drift, unstable practices, and informal workarounds.
- Ensure output is stable, predictable, and data-backed.
E. Quality, Rejection, and Process Capability- Own plant-level quality performance with Quality Head / team.
- Ensure process capability, in-process checks, reaction plans, containment actions, and defect prevention discipline.
- Lead response to internal rejection, customer complaints, repeat defects, and systemic process gaps.
- Ensure RCA is evidence-based and corrective actions are closed.
Your current JD rightly positions the Plant Head in quality assurance, design validation, root cause analysis, and supplier quality influence; that should stay, but with stronger ownership wording.
JD - Plant Head-Aluminium Forgi…
F. Maintenance, Reliability, and Asset Utilization- Ensure forging presses, furnaces, trimming equipment, compressors, utilities, and support equipment are available and reliable.
- Work with Maintenance to drive PM adherence, MTBF improvement, MTTR reduction, spares planning, and breakdown elimination.
- Escalate repeat failures and unresolved chronic losses.
- Drive better utilization of installed capacity before asking for capital expansion.
G. Tooling / Die and Process Performance Governance- Ensure close linkage between Tool Room, Process Engineering, and Production for die readiness, die life, setup quality, and process stability.
- Review die-related output loss, frequent die change, improper handling, trial inefficiency, and quality losses related to tooling condition.
- Hold the right function accountable using facts and review mechanisms.
H. NPD, Design and Manufacturability- Review new parts from manufacturability and plant capability point of view.
- Participate in APQP / feasibility / trial readiness discussions.
- Ensure new product introduction does not destabilize production performance.
- Coordinate Design, Process Engineering, Quality, Tool Room, and Production for robust industrialization.
This is already present in your current JD through collaboration with R&D, design feasibility, capacity planning, cross-functional coordination, and design validation.
JD - Plant Head-Aluminium Forgi…
I. People, Discipline, and Leadership Bench- Build second-line leadership across production, supervisors, shift in-charges, and support roles.
- Ensure discipline in attendance, shift handover, escalation, review action closure, and performance follow-through.
- Work with HR on hiring, retention, capability gaps, behavior issues, succession, and productivity-linked deployment.
- Build a culture of ownership, not excuse-making.
J. Safety, Compliance, and Audit Readiness- Lead plant safety culture and compliance with legal and internal safety standards.
- Ensure audit preparedness for production, safety, quality, environment, and statutory requirements.
- Ensure unsafe acts, unsafe conditions, and non-compliances are addressed immediately.
- Never compromise safety or integrity for short-term output.
As the Plant Head- Forging, your role is critical to New Product Development (NPD), Design & Quality, and Process Improvement. Let's explore the specific roles you would play in each of these areas as well:
New Product Development (NPD):
- Collaboration with R&D: You would collaborate with the Research and Development (R&D) team to understand upcoming product designs, specifications, and customer requirements. Your expertise in aluminum forging processes will be essential in assessing the feasibility of new products from a manufacturing perspective.
- Process Design and Feasibility: You will be responsible for evaluating the manufacturability of new product designs. By working closely with the engineering and design teams, you can provide valuable insights to ensure that the proposed products can be forged efficiently while meeting quality standards.
- Capacity Planning: As new products are introduced, you will need to assess the impact on production capacity and plan for any necessary adjustments in resources, machinery, and workforce to accommodate the increased workload.
- Cross-Functional Coordination: NPD involves multiple departments, including design, engineering, production, and quality assurance. You will play a crucial role in facilitating effective communication and collaboration among these teams to ensure successful product launches.
Design & Quality:
- Quality Management Systems: You will be responsible for implementing and maintaining robust quality management systems throughout the manufacturing process. This includes developing quality control procedures, conducting inspections, and ensuring compliance with relevant quality standards.
- Design Validation: As a subject matter expert in aluminum forging, you will review product designs and specifications to ensure they align with the plant's capabilities and are optimized for manufacturing efficiency without compromising product quality.
- Root Cause Analysis: In cases where quality issues arise, you will lead or participate in root cause analysis investigations to identify the underlying reasons and implement corrective actions to prevent recurrence.
- Supplier Quality Management: You may be involved in assessing and managing the quality of materials and components supplied to the plant. Collaborating with the procurement team, you can ensure that suppliers meet quality standards and contribute to the overall product quality.
Risk Management:
- Lean Manufacturing & Six Sigma: You will champion the implementation of Lean Manufacturing and Six Sigma methodologies to drive process improvements, reduce waste, and increase efficiency throughout the production process.
- Data Analysis: As the Plant Head, you will utilize data analysis to identify bottlenecks, inefficiencies, and opportunities for improvement in various stages of the forging process. Data-driven decisions will help in optimizing production and resource allocation.
- Continuous Improvement Culture: Instilling a culture of continuous improvement within the plant is essential. By encouraging and supporting employees to identify and propose process improvements, you can foster an environment that continually seeks to enhance operations.
- Automation & Technology: You will be involved in assessing the potential of automation and advanced technologies in aluminum forging processes to improve productivity and overall manufacturing capabilities.
Overall, your expertise and leadership in NPD, Design & Quality, and Process Improvement will be instrumental in driving innovation, ensuring product excellence, and optimizing the overall manufacturing efficiency of the Aluminium Forging Plant.
Click on Apply to know more.