Plant Manager (Operations & Administration)

Company: ZaaK Materials

Location: P.O. Lohgara, Vill-Khanshemra, Tehsil Bara, District Prayagraj, Uttar Pradesh

Department: Plant Operations

Reports to: Management / Director

Employment Type: Full-time

About the Role

We are looking for an experienced and hands-on Plant Manager Operations & Administration to take overall responsibility for the safe, efficient, and disciplined operation of our manufacturing facility.This role manages production, manpower, maintenance coordination, quality, inventory, dispatch, plant safety, statutory compliance, and general administration. The ideal candidate is a practical problem-solver who can work closely with management, production teams, suppliers, customers, and external agencies.You should be highly comfortable working in a start-up/scale-up manufacturing environment, where building systems and processes is as important as running daily operations.

Most Important Requirement: This is not a desk job. The chosen candidate must spend significant time on the plant floor, thoroughly understand the manufacturing process, supervise the team directly, and take ownership of problems until resolved.

Key Responsibilities

1. Plant Operations & Production

• Daily Operations: Take overall responsibility for day-to-day plant operations.
• Production Planning: Plan and execute production according to sales requirements and production schedules.
• Asset Utilization: Ensure optimum utilization of plant, machinery, manpower, and raw materials.
• Efficiency Monitoring: Monitor production output, productivity, downtime, and operational efficiency.
• Standard Operating Procedures: Establish and maintain standard operating procedures (SOPs) for production activities.
• Quality Assurance: Ensure consistent product quality and batch-to-batch uniformity.
• Bottleneck Removal: Identify operational bottlenecks and implement corrective actions.
• Documentation: Maintain proper production records, batch sheets, and plant documentation.

2. Manpower Management

• Supervision: Manage and supervise plant operators, workers, helpers, and support staff.
• Scheduling: Prepare manpower deployment and shift schedules.
• Availability: Ensure adequate manpower availability for production and dispatch.
• Performance Control: Set clear responsibilities and performance expectations for plant personnel.
• Discipline & Attendance: Monitor attendance, discipline, productivity, and overtime.
• Training: Train employees on production procedures, safety, and good housekeeping.
• Culture: Build a culture of accountability, cleanliness, and operational discipline. Quality & Process Control
• Cross-Functional Collaboration: Work closely with the Quality/Technical team to maintain product specifications.
• Material Control: Ensure proper control of raw materials and finished products.
• Deviation Resolution: Investigate production deviations, customer complaints, and quality issues.
• CAPA: Implement corrective and preventive actions.
• Testing Systems: Ensure proper sampling, testing, and documentation of batches.
• Traceability: Maintain traceability of raw materials and finished products.

4. Raw Material, Inventory & Warehouse

• Procurement: Coordinate procurement requirements based on production plans.
• Stock Control: Monitor availability and consumption of raw materials while maintaining appropriate inventory levels.
• Storage: Ensure proper storage and handling of raw materials and finished goods.
• Record Keeping: Maintain highly accurate stock records.

5. Maintenance & Equipment

• Asset Care: Ensure preventive and routine maintenance of plant machinery and equipment.
• Breakdown Handling: Coordinate with maintenance contractors/technicians for breakdowns and repairs.
• Reliability Metrics: Monitor equipment downtime and recurring failures.
• Schedules & Spares: Maintain maintenance schedules/records and ensure availability of critical spare parts.
• Continuous Improvement: Recommend equipment improvements and modifications where required.

6. Health, Safety & Environment (HSE)

• Safe Workplace: Take responsibility for maintaining a safe working environment.
• PPE & Safety Compliance: Ensure workers use appropriate PPE and follow safety procedures.
• Inspections: Conduct regular safety inspections and toolbox meetings.
• Housekeeping: Maintain exceptional plant cleanliness and proper housekeeping across the facility.
• Site Liaison: Coordinate with the host industrial facility/thermal power plant wherever required for site safety and access requirements.
• Statutory Safety: Ensure compliance with applicable environmental, fire, and safety requirements.

7. Plant Administration

• Facilities Management: Handle day-to-day plant administration and facilities management (security, housekeeping, transportation, and support services).
• Logs & Records: Maintain attendance, leave records, and plant-related documentation/registers.
• Access Control: Coordinate visitor access and plant entry requirements.
• Stakeholder Relations: Coordinate with local authorities, contractors, vendors, and service providers.
• Petty Cash: Manage petty cash and routine plant administrative expenses within approved limits.
• Licensing: Ensure timely renewal and maintenance of plant-related licenses, permits, contracts, and service agreements in coordination with management.

8. Dispatch & Logistics

• Outflow Planning: Coordinate finished-goods planning with the Sales/Commercial team.
• Loading & Timelines: Ensure timely and accurate loading and dispatch of products.
• Vendor Management: Coordinate transporters and loading/unloading activities to minimize dispatch delays.
• Reconciliation: Maintain dispatch documentation and stock reconciliation.

9. Cost Control

• Expense Management: Monitor manufacturing costs and identify opportunities for cost reduction.
• Waste Elimination: Control material wastage, energy consumption, overtime, and maintenance costs.
• Budget Tracking: Track actual production costs against budgets/targets.
• Profitability: Recommend measures to improve plant productivity and profitability.

10. Reporting to Management: Prepare regular, timely, and accurate operational reports covering:

• Production (daily/weekly/monthly)
• Raw material consumption and inventory
• Finished goods inventory & dispatch logistics
• Manpower, attendance, and plant downtime
• Maintenance schedules and quality issues
• Safety incidents and manufacturing costs
• Operational challenges and immediate corrective actions