Plant Head

Job Summary Responsibilities

• Plant Establishment/Setup Phase
• Facility planning: Plan and design the shop-floor layout for pipe spool fabrication (cutting, beveling, fit-up, welding, NDE, PWHT, blasting/painting, and dispatch bays) to achieve 60,000 dia-inch/month across two shifts.
• Capacity planning: Prepare capacity, manpower, machinery, and utility requirement plans, and finalize capex/opex budgets for plant setup.
• Machinery selection: Identify, specify, and select fabrication and welding equipment (SAW/GTAW/GMAW, orbital welding, pipe beveling machines, rolling/bending machines, cranes, EOT, cutting and fit-up jigs) suited for stainless steel spool fabrication.
• Installation commissioning: Coordinate procurement, installation, and commissioning of plant and machinery, including vendor selection, equipment trials, and utility tie-ins (power, compressed air, argon/shielding gas, ventilation, fume extraction).
• Manpower build-up: Recruit, structure, and onboard the production team; welders (WPS/WPQ qualified), fitters, QC/NDE inspectors, planners, supervisors, and support staff; for two-shift operations.
• ASME/QMS systems: Set up welding procedure specifications (WPS), procedure qualification records (PQR), and welder qualification records (WQR/WPQ) in line with ASME Section IX.
• Quality systems: Establish the quality management system, inspection and test plans (ITPs), NDE protocols (RT/UT/PT/MT), material traceability, and documentation control in compliance with ASME B31.3 and customer/project specifications.
• Safety statutory compliance: Set up safety systems, PPE protocols, hot-work permits, and statutory compliances (factory license, pollution control, fire safety) required for plant operation in Chakan.
• Systems processes: Define SOPs, production planning and control systems, ERP/production tracking tools, and KPIs ahead of go-live.
• Plant Operations Phase (Post-Commissioning)
• Production management: Take full ownership of day-to-day plant operations across two shifts to consistently achieve the rated output of 60,000 dia-inch of SS pipe spools per month.
• Planning scheduling: Drive production planning and scheduling, shift-wise manpower deployment, machine utilization, and on-time delivery of fabricated spools against project/customer schedules.
• Code compliance: Ensure all fabrication activities; cutting, beveling, fit-up, welding, PWHT, and testing; are executed strictly per approved WPS/PQR, ASME B31.3, and applicable ASME/ASTM/customer standards.
• Quality assurance: Own quality outcomes; first-time-right rate, NDE clearance rate, weld repair rate; and drive root-cause analysis and corrective/preventive actions for non-conformances.
• Cost control: Monitor and control cost of production, material yield/scrap (SS plate, pipe, and consumables), welding consumable usage, and overall plant operating costs against budget.
• Inventory materials: Plan and control raw material (SS pipes, fittings, flanges, consumables) inventory and coordinate with procurement/stores to avoid production stoppages.
• Safety, health environment: Implement and enforce EHS standards, permit-to-work systems, and safe welding/fabrication practices; drive a zero-incident culture across both shifts.
• Team leadership: Lead, train, and appraise supervisors, welders, and QC staff; build a two-shift roster that sustains capacity and reduces attrition of skilled welders.
• MIS continuous improvement: Report plant performance (production, quality, cost, safety, manpower) to management; drive continuous improvement, debottlenecking, and capacity enhancement initiatives.
• Customer TPI interface: Act as the primary technical/operational interface with clients, TPI agencies, and third-party inspectors for approvals, audits, and project reviews

Required Skills

• Strong grasp of fabrication shop layout, capacity planning, and lean manufacturing principles.
• Hands-on knowledge of welding processes, WPS/PQR/WPQ documentation, and NDE methods.
• Proven ability to set up a greenfield plant; machinery, manpower, systems; from scratch.
• Strong people management skills to run multi-shift operations and retain skilled welding manpower.
• Cost consciousness, data-driven decision making, and familiarity with ERP/production MIS tools.
• Strong commitment to safety, quality, and on-time delivery under project timelines.

Required Qualification Key Skills

• ASME/QMS Systems
• Manpower Build-up