Plant Manager - Ceramics

1.Role Overview
The Plant Manager - Ceramics shall be responsible for the overall management and performance of the manufacturing plant including production, maintenance, utilities, quality, safety, commercial coordination, statutory compliance, manpower management, and cost control. The role will ensure safe, efficient, and profitable plant operations while achieving production targets, quality standards, and operational excellence.
2.Key Responsibilities
A.Overall Plant Operations

• Lead end-to-end plant operations including production, maintenance, utilities, stores, dispatch, and administration. 
• Ensure achievement of production targets with optimum utilization of manpower, machinery, raw materials, and utilities. 
• Drive operational efficiency, productivity improvement, and cost optimization across plant functions. 
• Monitor daily plant performance and ensure smooth operation of the Electric Arc Furnace and associated systems. 

B.Production Management

• Plan and monitor production schedules as per business requirements.
• Ensure product quality, process stability, and adherence to technical specifications. 
• Improve productivity, yield, and operational efficiency. 
• Coordinate with marketing and commercial teams for production planning and dispatch commitments.

C.Maintenance & Utilities

• Oversee maintenance of plant machinery, utilities, HT/LT systems, transformers, substations, DG sets, compressors, and furnace systems. 
• Ensure effective preventive and predictive maintenance systems. 
• Minimize plant downtime and improve equipment reliability. 
• Ensure uninterrupted availability of power, water, fuel, and utilities. 

D.Furnace & Process Operations

• Supervise operation and efficiency of the 3 MVA Electric Arc Furnace.
• Ensure safe and energy-efficient furnace operations. 
• Monitor refractory performance, power consumption, electrode consumption, and process optimization. 
• Lead troubleshooting and operational improvements for process stability. 

E.Safety, Environment & Compliance

• Ensure strict compliance with safety regulations, environmental norms, factory laws, and statutory requirements. 
• Promote a strong safety culture and ensure zero major accidents. 
• Ensure compliance with Pollution Control Board, Electrical Inspectorate, Factory Inspectorate, and other regulatory bodies. 
• Conduct regular safety audits and compliance reviews. 

F.Quality Assurance & Process Improvement

• Ensure implementation of quality systems and process controls. 
• Reduce rejection, rework, and process losses. 
• Drive continuous improvement initiatives including Lean Manufacturing, TPM, and operational excellence programs. 
• Monitor customer complaints and ensure corrective actions. 

G.Cost Control & Resource Optimization

• Monitor plant operational costs including power, fuel, consumables, manpower, and maintenance expenses. 
• Drive initiatives for energy conservation and cost reduction. 
• Optimize inventory levels of raw materials, consumables, and spares. 
• Prepare and manage plant budgets and operational MIS reports. 

H.Team Leadership & Industrial Relations

• Lead and develop cross-functional plant teams. 
• Ensure discipline, productivity, and workforce engagement. 
• Coordinate with HR for manpower planning, recruitment, training, and performance management. 
• Maintain healthy industrial relations and handle workforce-related matters effectively. 

I.Projects & Expansion

• Support plant expansion, modernization, and capex projects. 
• Coordinate installation and commissioning of new machinery and equipment. 
• Drive automation and process improvement initiatives.

3.Qualifications & Experience

• B.E./B.Tech in Mechanical / Electrical / Metallurgical / Production Engineering 
• MBA (Operations) preferred
• 15+ years of experience in manufacturing industries such as Refractory, Steel, Ferro Alloys, Metals, Ceramics, or Heavy Engineering 
• Minimum 5–8 years in senior plant leadership role

4.Key Skills & Competencies

• Experience in managing Electric Arc Furnace (EAF) operations, utilities, production, maintenance, quality, and plant administration preferred