Control Panel Unit- Head

Job Description - Control Panel Unit Head

Function: Manufacturing
Department: Control Panel Manufacturing
Location: Coimbatore, Tamil Nadu
Reporting To: Operations Head / Plant Head
Grade: Senior Management (Based on Organization Structure)
Industry Preference: Control Panel Manufacturing, Electrical Equipment, Switchgear, Automation, Renewable Energy, Wind Energy, Electronics Manufacturing, Industrial Equipment.

Job Purpose

To lead and manage the overall operations of the Control Panel Manufacturing Unit, ensuring achievement of production, quality, delivery, safety, cost, and customer satisfaction targets. The role is responsible for end-to-end manufacturing operations including planning, procurement coordination, stores, production, quality, testing, dispatch, maintenance, EHS, manpower management, and continuous improvement initiatives while ensuring compliance with business objectives and statutory requirements. [CPU JD- Plant Head | Excel]

Direct Reports

• Production Managers / Supervisors
• Quality Manager
• PPC Executive / Manager
• Testing & Dispatch Team
• Maintenance Team
• Stores & Inventory Team
• Engineering / Process Improvement Team

Indirect Reports

• Production Engineers
• Quality Engineers
• Technicians
• Operators
• Contract Workforce

Key Accountabilities

1. Production Management

• Ensure smooth functioning of all control panel manufacturing processes:
• Sheet Metal Enclosure Assembly
• Busbar Fabrication & Assembly
• Component Mounting
• DIN Rail Assembly
• Wiring & Harness Preparation
• Internal Wiring & Interconnections
• PLC, HMI and Controller Integration
• Power and Control Circuit Assembly
• Labeling & Identification
• Panel Inspection & Testing
• Final Assembly & Packing
• Achieve production targets as per business plan and customer schedules.
• Monitor productivity and capacity utilization of the plant.

Performance Measures

• Production achievement %
• OTIF Delivery
• Capacity utilization
• Productivity per employee

2. Production Planning & Delivery

• Ensure adherence to production plans released by Central Planning/PPC.
• Coordinate with procurement, stores and production teams for material readiness.
• Drive on-time dispatch of finished control panels.
• Monitor production loading and resource allocation.

Performance Measures

• Plan vs Actual Production
• Schedule Adherence
• Customer Delivery Performance

3. Quality Excellence

• Establish robust quality management systems across manufacturing processes.
• Monitor incoming, in-process and final quality controls.
• Drive reduction of quality defects, rework and customer complaints.
• Ensure adherence to customer specifications and quality standards.
• Lead internal and external quality audits.

Performance Measures

• First Pass Yield (FPY)
• Customer Complaints
• Rejection PPM
• Rework Percentage

4. Testing & Product Reliability

• Ensure 100% testing of control panels before dispatch.
• Verify functionality of PLC, relays, protection systems, communication modules and electrical circuits.
• Oversee implementation of testing protocols and quality documentation.

Performance Measures

• Testing Compliance
• Field Failure Rate
• Dispatch Quality Performance

5. Cost Management & Budget Control

• Prepare and manage annual operational budgets.
• Control manufacturing costs and improve operational efficiency.
• Monitor labor, material and overhead costs.
• Drive cost reduction and value engineering projects.

Performance Measures

• Manufacturing Cost per Panel
• Budget Adherence
• Cost Saving Projects Implemented

6. Inventory & Material Management

• Ensure availability of raw materials, bought-out components and consumables.
• Coordinate with procurement and supplier teams to minimize shortages.
• Optimize inventory levels and reduce excess stock.

Performance Measures

• Inventory Turnover
• Material Availability
• Inventory Accuracy

7. Continuous Improvement

• Lead Lean Manufacturing, Kaizen, TPM and 5S initiatives.
• Improve plant efficiency and reduce non-value-added activities.
• Drive cycle time reduction and productivity enhancement projects.

Performance Measures

• Kaizen Implementations
• Productivity Improvement %
• Cycle Time Reduction

8. Maintenance & Asset Management

• Ensure preventive and predictive maintenance of equipment and utilities.
• Improve equipment reliability and Overall Equipment Effectiveness (OEE).
• Monitor uptime of critical manufacturing equipment.

Performance Measures

• OEE
• Equipment Uptime
• Breakdown Hours

9. Safety, Health & Environment (EHS)

• Ensure compliance with EHS standards and company safety requirements.
• Lead safety committees, audits and risk assessments.
• Promote a culture of zero accidents and safe working practices.

Performance Measures

• Lost Time Injury Frequency Rate (LTIFR)
• Near Miss Closure
• Safety Audit Compliance

10. Quality Management Systems & Compliance

• Ensure implementation and maintenance of:
• ISO 9001
• ISO 14001
• ISO 45001
• Ensure compliance with statutory and customer requirements.
• Drive audit readiness and closure of audit observations.

Performance Measures

• Audit Findings
• Compliance Status
• Certification Retention

11. People Management

• Lead, mentor and develop manufacturing teams.
• Build succession plans and competency development programs.
• Drive employee engagement, welfare and performance management.

Performance Measures

• Attrition Rate
• Training Hours
• Employee Engagement Score

12. Customer Satisfaction

• Support customer audits and business reviews.
• Ensure timely closure of customer concerns.
• Drive improvements based on customer feedback.

Performance Measures

• Customer Satisfaction Index
• Complaint Closure Time
• OTIF Performance

Prior Exposure & Experience

• Experience in Control Panel Manufacturing, Electrical Equipment Manufacturing, Switchgear, Automation Systems, Renewable Energy Equipment, Wind Energy, Power Electronics or Industrial Electrical Products.
• Experience managing complete manufacturing operations of a plant or business unit.
• Exposure to Lean Manufacturing, TPM, Six Sigma and Quality Systems.

Educational Qualification

• B.E./B.Tech in Electrical, Electronics, Instrumentation, Mechanical or Production Engineering.
• MBA/PGDM in Operations Management preferred.

Experience Required

• 15-20+ years of manufacturing experience.
• Minimum 5 years in a plant leadership / manufacturing leadership role.
• Experience in managing end-to-end control panel manufacturing operations.

Functional Competencies

• Manufacturing Operations Management
• Production Planning & Control
• Electrical Control Panel Manufacturing
• Quality Management Systems
• Lean Manufacturing & TPM
• Supply Chain Coordination
• Inventory Management
• Cost Control & Budgeting
• EHS Management
• Customer & Stakeholder Management

Leadership Competencies

• Strategic Thinking
• Decision Making
• Planning & Organizing
• Team Building
• Result Orientation
• Problem Solving
• Change Management
• Customer Focus
• Business Acumen

Key Success Metrics

Financial

• Manufacturing Cost Reduction
• Budget Adherence
• Inventory Value Optimization

Non-Financial

• Production Achievement
• OTIF Delivery
• Quality Performance
• OEE Improvement
• Safety Performance
• Customer Satisfaction
• Employee Engagement