Plant Head - Second Level

Plant Head Sleeper Plant is responsible for the end-to-end management of a sleeper-manufacturing plant (concrete and/or composite), ensuring safe, reliable, efficient, and high-quality production of sleepers in alignment with Patil Groups strategic objectives. This role will drive operational excellence, cost optimization, capacity scaling, and quality/reliability, while leading a cross-functional manufacturing team.

Key Responsibilities:

1 Operational Leadership & Production

• 1.1 Oversee all manufacturing operations of the sleeper plant, including raw material handling, prestressing, casting, demoulding, curing, and finishing.
• 1.2 Implement and maintain Long Line Technology or similar automated systems to maximize throughput, minimize cycle time, and reduce waste.
• 1.3 Ensure production targets (volume, mix, shift utilization) are met in line with business forecasts.
• 1.4 Develop and manage plant capacity plans (short-term and long-term), identifying bottlenecks and executing capacity expansion or optimization projects.
• 2 Quality Assurance & Compliance
• 2.1 Ensure sleepers meet stringent quality standards (dimensional, strength, durability) as per internal and customer (e.g., Indian Railways) specifications.
• 2.2 Lead root-cause analysis for rejects or defects; drive corrective & preventive actions (CAPA).
• 2.3 Ensure compliance with statutory and regulatory requirements (safety, environment, labor), including internal audits.

3 Safety, Health & Environment (HSE)

• 3.1 Champion a zero-harm safety culture in the plant.
• 3.2 Monitor and manage leading and lagging HSE indicators (near misses, incidents, unsafe acts), driving behavior-change programs.
• 3.3 Lead risk assessments, HSE training, and implementation of safety protocols.

4 Cost & Efficiency Management

• 4.1 Drive cost optimization through efficient use of raw materials, utilities (power, water), labor, and process improvements.
• 4.2 Implement lean manufacturing / continuous improvement initiatives (e.g., Kaizen) to reduce waste, rework, downtime.
• 4.3 Optimize plant OEE (Overall Equipment Effectiveness) by maximizing uptime, performance, and quality.

5 People Leadership & Team Management

• 5.1 Lead and develop the plant management team production, maintenance, quality, safety, and logistics.
• 5.2 Build capability: talent development, succession planning, training, and performance management.
• 5.3 Foster a culture of accountability, continuous improvement, innovation, and high performance.

6 Reporting & Stakeholder Management

• 6.1 Provide regular reports to Corporate HQ (Hyderabad) on performance (production, quality, cost, safety).
• 6.2 Liaise with senior leadership (Operations, Strategy, Finance) to align plant operations with Group goals.
• 6.3 Engage with external stakeholders (e.g., customers, auditors, regulators) as needed.

7 Supply Chain & Logistics Interface

7.1 Coordinate with procurement for raw materials (cement, steel wire, etc.) to ensure uninterrupted supply.

7.2 Work with logistics teams to ensure timely outbound delivery of sleepers to customers / storage.

8 Strategic Projects & Innovation

8.1 Pilot and implement new technologies (e.g., higher-grade concrete, improved prestressing wire) in the plant.

8.2 Collaborate with R&D / Design centers to introduce process innovations and design improvements.

8.3 Lead capacity expansion or greenfield projects (if relevant), including cost estimation, project execution, and commissioning. Qualifications: B.E/ B.Tech (Mechanical) Experience Required: 15-20 years

Industry: Any manufacturing / Automobile /RMC/Prefabrication Industry, Precast Structures/Hume Pipe etc. Key Skills & Competencies: Leadership & Strategic Thinking Operational Excellence / Execution Quality Management Safety & Compliance Business Acumen Communication & Reporting Project Management People Management Key Performance Indicators (KPIs): % Monthly production target achieved % Capacity utilized Reject/ Scrap rate reduction Number of near misses reported HSE audit score Cost per sleeper produced Energy consumption per unit Planned Vs. Unplanned downtime % Reduction in attrition rate Training hours per employee On time delivery of projects Number of process improvements Budget adherence of projects Savings from process innovations