Plant Manager

Role & responsibilities

Job Description

Plant Operations Manager Putty & Tile Adhesive Manufacturing Plant

Position

Designation: Plant Operations Manager
Department: Manufacturing / Operations
Industry: Construction Chemicals / Building Materials
Reporting To: General Manager / Head of Operations / Plant Head
Location: [Plant Location]
Experience: 815 years in manufacturing, preferably construction chemicals, dry-mix mortar, wall putty, tile adhesive, or related products.

Job Purpose

To manage and control the complete plant operations for the manufacturing of wall putty, tile adhesive, and other dry-mix construction chemical products, ensuring safe, efficient, cost-effective, and uninterrupted production while maintaining required quality standards and delivery schedules.

Key Responsibilities

1. Production & Plant Operations

• Plan, supervise, and control daily production activities as per production targets and customer requirements.
• Ensure efficient operation of mixers, conveyors, silos, packing machines, compressors, dust-collection systems, and other plant equipment.
• Prepare production plans and ensure timely execution.
• Monitor production output, machine utilization, material consumption, and process losses.
• Optimize manpower, machinery, and raw-material utilization.
• Ensure minimum downtime and effective utilization of plant capacity.
• Coordinate production of different grades/formulations of wall putty and tile adhesive.

2. Raw Material & Process Control

• Coordinate with Purchase, Stores, R&D, and Quality teams for timely availability and release of raw materials.
• Monitor consumption of cement, fillers, polymers, additives, chemicals, pigments, and other raw materials.
• Control material wastage and production losses.
• Ensure proper batch-wise manufacturing and traceability.
• Maintain process parameters and standard operating procedures (SOPs).

3. Quality Control

• Work closely with the Quality Control/Laboratory team to maintain product specifications.
• Ensure adherence to approved formulations and manufacturing procedures.
• Investigate production-related quality deviations and implement corrective actions.
• Minimize rejection, rework, customer complaints, and batch variations.
• Ensure proper sampling, testing, and documentation of production batches.

4. Maintenance & Equipment Reliability

• Coordinate with the maintenance team for preventive and breakdown maintenance.
• Monitor machine performance and recurring equipment problems.
• Develop preventive-maintenance schedules to reduce breakdowns.
• Ensure availability of critical spare parts.
• Improve equipment reliability, productivity, and energy efficiency.

5. Manpower Management

• Manage production supervisors, operators, technicians, helpers, and contract workers.
• Allocate manpower according to production requirements.
• Train employees on operating procedures, safety, quality, and productivity.
• Monitor attendance, discipline, productivity, and performance.
• Develop a culture of accountability and continuous improvement.

6. Safety & Environmental Compliance

• Ensure strict compliance with plant safety procedures.
• Conduct regular safety inspections and toolbox meetings.
• Ensure proper use of PPE and safe handling of chemicals and raw materials.
• Maintain housekeeping and 5S standards throughout the plant.
• Ensure compliance with applicable environmental, fire, statutory, and factory regulations.
• Investigate accidents/incidents and implement preventive measures.

7. Cost & Productivity Improvement

• Control manufacturing costs through efficient use of raw materials, manpower, energy, and machinery.
• Monitor key production KPIs such as:
  
• Production quantity
• Production yield
• Material variance
• Machine downtime
• OEE
• Rejection/rework
• Labour productivity
• Energy consumption
• Manufacturing cost per MT
• Identify and implement productivity and cost-reduction initiatives.
• Drive continuous improvement and process optimization.

8. Planning & Coordination

• Coordinate with Sales, Dispatch, Purchase, Stores, Quality, Maintenance, and Finance departments.
• Ensure production is aligned with dispatch requirements.
• Monitor inventory of raw materials, packaging materials, and finished goods.
• Escalate production constraints and operational issues to management.
• Prepare daily, weekly, and monthly production reports.

Preferred candidate profile

• Production planning and execution
• Team leadership and manpower management
• Problem-solving and decision-making
• Process optimization
• Cost control
• Quality orientation
• Maintenance coordination
• Safety management
• Data analysis and MIS reporting
• Cross-functional coordination
• Continuous improvement mindset