Plant Head Transformer Manufacturing

Role & responsibilities

Key Responsibilities

1. Production Planning & Execution

* Prepare daily, weekly and monthly production plans based on committed delivery schedules.

* Plan and coordinate activities across winding, core, assembly, tanking, ovening, oil filtration, testing and dispatch.

* Monitor production against targets and identify bottlenecks affecting delivery.

* Ensure availability and proper allocation of manpower, machines, materials and other resources.

* Coordinate with Purchase, Stores, Design and Quality teams to prevent production delays.

* Improve productivity and reduce manufacturing cycle time and rework.

2. Quality & Process Control

* Lead and guide the Quality team for incoming, in-process and final inspection.

* Ensure adherence to approved drawings, GTPs, manufacturing procedures and applicable IS/IEC/customer specifications.

* Establish appropriate stage-wise quality checks and hold points.

* Ensure proper documentation and traceability of critical manufacturing activities.

* Drive reduction in rejection, rework and recurring quality issues.

3. Root Cause Analysis & Troubleshooting

A major requirement of this position is the ability to technically investigate manufacturing and testing failures.

The Plant Head should be able to:

* Investigate in-process failures and abnormalities.

* Perform structured Root Cause Analysis (RCA).

* Identify whether the problem originates from design, material, workmanship, process or testing.

* Define and implement Corrective and Preventive Actions (CAPA).

* Guide the team in troubleshooting issues such as:

* Low IR/Megger values

* Ratio/tap-position abnormalities

* High resistance or unbalance

* Excessive losses

* Impedance deviations

* HV/LV withstand failures

* Induced/DVDF test failures

* Oil leakage

* Temperature-rise related issues

* Other routine and type-test abnormalities

* Maintain records of major failures and ensure learning is incorporated into future manufacturing.

4. Testing & Customer Inspections

* Ensure transformers are completely ready before customer/third-party inspection.

* Review internal test results before offering transformers for inspection.

* Coordinate and handle inspections by customers, utilities and third-party agencies.

* Technically represent the company during inspections and resolve observations raised by inspectors.

* Ensure testing is carried out according to applicable IS/IEC standards and approved specifications.

* Ensure inspection observations and NCRs are closed within defined timelines.

5. Team Leadership

* Lead Production, Quality and Testing teams and establish clear accountability.

* Conduct regular production and quality review meetings.

* Guide engineers and supervisors in solving day-to-day technical and operational problems.

* Develop technical capability of junior engineers through practical training and mentoring.

* Maintain discipline, safety and coordination across departments.

* Evaluate manpower requirements and support recruitment and development of the plant team.

6. After-Sales & Site Support

* Technically guide the after-sales/service team for transformer-related complaints.

* Analyse customer complaints and determine probable root causes before deputing teams to site.

* Guide site teams regarding required checks, instruments and corrective actions.

* Review site failure reports and determine whether issues relate to manufacturing, installation, protection, loading or site conditions.

* Ensure customer complaints are closed quickly while protecting the companys technical and commercial interests.

* Feed learnings from site failures back into Production, Design and Quality.

7. Dispatch & Delivery Responsibility

* Ensure transformers are technically and commercially ready for dispatch as per committed schedules.

* Review pending jobs and proactively escalate risks to delivery.

* Coordinate inspection clearance, testing documentation, accessories, packing and dispatch readiness.

* Ensure transformers are dispatched without pending technical or quality issues.

8. Continuous Improvement

* Identify bottlenecks and opportunities for improvement across manufacturing processes.

* Implement systems for reducing rejection, rework, testing failures and production delays.

* Develop SOPs, checklists and process controls for critical activities.

* Track recurring problems and ensure permanent corrective action rather than temporary solutions.

* Promote 5S, workplace safety and preventive maintenance practices.

Key Performance Indicators (KPIs)

Performance of the Plant Head will primarily be measured on:

* On-time production and dispatch

* Production plan vs. actual achievement

* First-pass testing success rate

* In-process rejection and rework

* Customer inspection clearance / first-time acceptance

* Reduction in recurring quality failures

* Customer/site complaint closure time

* Manufacturing cycle time

* Productivity and manpower utilisation

* Compliance with quality and safety systems