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Job Description - Plant Head (Washing Machine Manufacturing)
Location: Noida, Uttar Pradesh
Reports to: Managing Director
Team size: ~200 (direct + indirect)
CTC: ₹12 LPA
Department: Manufacturing / Operations
Role Summary
Own end-to-end plant operations for washing machine manufacturing - injection moulding, sub-assembly, and final assembly lines. The role carries full accountability for production planning, output, quality, manpower, cost control and plant discipline. The right person is a hands-on moulding expert who can also run a shop floor of 200 people and defend a costing sheet in front of management.
Key Responsibilities
#Moulding
- Full technical ownership of the injection moulding shop — machine setting, process parameters, cycle time optimisation, material drying, shot weight and rejection control.
- Mould maintenance and repair: preventive maintenance schedules, trial runs, troubleshooting short shots, flash, warpage, sink marks, weld lines, and colour/streak issues.
- Coordinate with tool room and mould suppliers on new mould development, T0/T1 trials and corrections.
- Control regrind usage, scrap generation and material yield.
#Assembly & Production
- Plan and execute daily, weekly and monthly production schedules for washing machine models against the sales/dispatch plan.
- Line balancing, manpower deployment, cycle time and takt time management across assembly lines.
- Drive OEE, first-pass yield and on-time dispatch; escalate and resolve line stoppages.
- Coordinate with stores, purchase and quality to prevent line-down situations.
#Materials
- Working knowledge of plastics (PP, ABS, HIPS, PC blends), masterbatch, sheet metal, motors, gearboxes, wiring harness, PCBA and packaging materials.
- Material planning, BOM validation, inventory norms, WIP control and shortage management.
- Support vendor development and material cost reduction initiatives.
#Costing & Reporting (Excel)
- Build and maintain product costing sheets — material cost, conversion cost, moulding cost per part, labour, overheads and scrap cost.
- Strong command of Excel: pivot tables, VLOOKUP/XLOOKUP, SUMIFS, conditional formatting, dashboards and MIS reports for management review.
- Track cost per unit, rejection cost, power/utility consumption and productivity metrics month-on-month.
#Leadership & People
- Lead a plant team of approximately 200 including supervisors, operators, technicians, quality and stores staff.
- Shift planning, attendance, discipline, training, skill matrix and contract labour management.
- Drive 5S, Kaizen, safety and statutory compliance on the shop floor.
- Build a performance culture with clear daily targets and review discipline.
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#Candidate Requirements
- Diploma or B.E./B.Tech in Mechanical, Plastics, Production or Electrical Engineering. Plastics/Tool engineering (CIPET) strongly preferred.
- 12–18 years in manufacturing, with at least 4–5 years as Plant Head / Works Manager / Production Head.
- Mandatory: hardcore injection moulding background with hands-on mould repair capability — not supervisory-only exposure.
- Experience in white goods, home appliances or high-volume plastics assembly. Washing machine experience is a strong plus.
- Proven record of managing 150+ workforce.
- Advanced Excel. ERP exposure (SAP/Tally/other) preferred.
- Knowledge of ISO 9001 systems, BIS requirements and basic labour compliance.
- Strong leadership, ownership, problem-solving and communication in Hindi and English.
#Key Performance Indicators
| Area | Metric |
|---|---|
| Production | Plan vs actual adherence, daily output |
| Quality | Moulding rejection %, assembly FPY, customer complaints |
| Cost | Cost per unit, scrap %, material yield |
| Machine | OEE, moulding downtime, mould breakdown hours |
| People | Absenteeism, attrition, productivity per head |
| Safety | Zero lost-time incidents, 5S score |
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