Operations Head (Corrugation Manufacturing Plant)

Location: Jalgaon, Maharashtra
Department: Corrugation / Carton Manufacturing

Position Summary

The Operations Head will be responsible for leading the complete operations of the Corrugation Manufacturing Plant, ensuring achievement of production, quality, cost, delivery, safety, and profitability targets. The role will drive operational excellence, business growth, continuous improvement, and customer satisfaction while maximizing plant capacity and operational efficiency.

Key Responsibilities

1. Plant Operations

• Lead end-to-end corrugation manufacturing operations including Corrugator, Printing, Die Cutting, Folder Gluer, Stitching, Pasting, Bundling, and Dispatch.
• Ensure achievement of production targets as per production planning.
• Optimize machine utilization, plant capacity, OEE, and productivity.
• Monitor daily production performance and eliminate operational bottlenecks.

2. Production Planning & Customer Delivery

• Ensure adherence to production schedules and customer delivery commitments.
• Achieve On-Time Delivery (OTD) targets.
• Coordinate with Sales, Planning, Stores, Procurement, and Dispatch for smooth order execution.
• Balance production priorities based on customer requirements.

3. Quality Management

• Ensure products meet customer specifications and quality standards.
• Drive First Time Right (FTR), Root Cause Analysis (RCA), CAPA, and continuous quality improvement.
• Reduce customer complaints, internal rejection, and rework.
• Support customer audits and quality system compliance.

4. Cost Optimization & Profitability

• Reduce paper wastage, board conversion losses, ink, adhesive, and consumable consumption.
• Improve material yield, manpower productivity, and machine efficiency.
• Lead value engineering and cost reduction initiatives.
• Drive profitability through operational excellence.

5. Inventory & Material Management

• Ensure optimum inventory levels of paper, ink, adhesives, and consumables.
• Maintain inventory accuracy through SAP/ERP and physical verification.
• Implement FIFO and effective warehouse management practices.
• Coordinate with Procurement to ensure uninterrupted material availability.

6. Maintenance & Engineering

• Ensure preventive and predictive maintenance of all manufacturing equipment.
• Minimize machine breakdowns and improve equipment reliability.
• Drive automation and technology improvement initiatives.
• Monitor utilities and equipment performance.

7. Lean Manufacturing & Continuous Improvement

• Implement Lean Manufacturing, TPM, OEE, Kaizen, 5S, SMED, Poka-Yoke, and Visual Management practices.
• Improve productivity, efficiency, and process capability.
• Eliminate waste and standardize manufacturing processes.
• Lead continuous improvement projects across the plant.

8. Safety, Environment & Compliance

• Ensure compliance with statutory, environmental, and safety regulations.
• Promote Zero Accident culture and safe working practices.
• Conduct regular safety audits and risk assessments.
• Maintain high standards of housekeeping and discipline.

9. Team Leadership & Development

• Lead Production, Quality, Maintenance, Stores, Planning, and Dispatch teams.
• Build a high-performance culture through coaching, mentoring, and training.
• Develop successors and strengthen organizational capability.
• Foster accountability, teamwork, and continuous learning.

10. Business Opportunities Identification & Execution

• Identify new business opportunities to maximize plant capacity utilization and revenue.
• Work closely with Sales and Customers to develop new packaging solutions and products.
• Evaluate feasibility of new business opportunities and support successful project execution.
• Drive new product development, localization, and strategic business expansion initiatives.
• Support customer acquisition, retention, and long-term business growth.

11. Business Performance & Operational Excellence

• Drive achievement of Production Plan vs. Actual, OEE, OTD, Productivity, Quality, Inventory Accuracy, Cost Reduction, and Profitability targets.
• Monitor operational performance through SAP/ERP, MIS, and KPI reviews.
• Improve plant efficiency through data-driven decision-making.
• Support capacity expansion and future business growth initiatives.

Educational Qualification

• Bachelor's Degree in Mechanical, Production, Industrial, Packaging, Paper Technology, or related Engineering discipline.
• MBA (Operations) preferred.

Experience

• 10+ years of experience in Corrugation, Carton Manufacturing, Packaging, or Paper Converting Industry.
• Minimum 5 years in a Plant Head / Operations Head / Manufacturing Head role.
• Experience in high-volume automated corrugation plants.

Required Competencies

• Strong knowledge of corrugation manufacturing processes, packaging operations, and plant management.
• Expertise in Lean Manufacturing, TPM, OEE, Kaizen, 5S, SMED, SAP/ERP, and Continuous Improvement.
• Strong leadership, business acumen, analytical thinking, and decision-making skills.
• Excellent communication, customer management, planning, and cross-functional coordination.
• Proven ability to drive operational excellence, cost optimization, business growth, and team development.