Production Manager - Rod Mill

Contact - [phone removed].

Job Location - Jalan Complex, Gate no - 1. Howrah.

Local Male Candidates Prefer.

Rod Mill Production Manager: Job Responsibilities

1. Production Planning & Control

• Plan and execute daily, weekly and monthly rod mill production targets.
• Ensure production meets required quantity, quality and delivery schedules.
• Prepare production plans according to customer orders and raw-material availability.
• Monitor mill output, production rate, yield and material consumption.
• Minimize production losses, rejection, cobbles and downtime.

2. Rod Mill Operations

• Supervise the complete rolling process from billet charging to finished wire rod/coils.
• Monitor reheating furnace, roughing mill, intermediate mill, finishing mill, laying head and coil handling operations.
• Ensure correct rolling temperature, speed, pass schedule and dimensional parameters.
• Monitor mill parameters and optimize production efficiency.
• Troubleshoot operational problems and coordinate corrective actions.

3. Manpower Management

• Manage operators, supervisors, technicians and contract manpower.
• Allocate manpower according to shift and production requirements.
• Prepare shift schedules and ensure proper workforce utilization.
• Train employees on machine operation, quality, safety and process procedures.
• Evaluate employee performance and identify training requirements.

4. Quality Control

• Ensure finished wire rods meet required size, chemistry, mechanical properties and surface quality.
• Coordinate with the Quality/QA department regarding process and product quality.
• Investigate customer complaints, rejection and quality deviations.
• Implement corrective and preventive actions.
• Maintain production and quality records.

5. Maintenance Coordination

• Coordinate with Mechanical, Electrical and Instrumentation teams for preventive and breakdown maintenance.
• Monitor critical equipment condition and reduce unplanned downtime.
• Participate in root-cause analysis of repeated equipment failures.
• Ensure proper availability of rolls, guides, bearings and other critical spares.
• Plan shutdown maintenance activities with the maintenance team.

6. Safety & Compliance

• Ensure strict compliance with plant safety rules and SOPs.
• Conduct toolbox talks and safety briefings.
• Identify operational hazards and implement preventive measures.
• Ensure proper use of PPE and safe working practices.
• Investigate and report accidents/incidents and implement corrective actions.

7. Cost & Productivity Improvement

• Control consumption of power, fuel, water, rolls, lubricants and other consumables.
• Improve yield, productivity and Overall Equipment Effectiveness (OEE).
• Reduce scrap, scale loss and process wastage.
• Identify opportunities for automation and process improvement.
• Implement Lean/Kaizen/5S initiatives where applicable.

8. MIS & Reporting

• Prepare daily production reports and shift performance reports.
• Track KPIs such as:
• Production MT/day
• Yield %
• Mill utilization %
• OEE
• Rejection %
• Downtime
• Energy consumption/MT
• Rolling speed
• Billet-to-coil conversion
• Present production performance to senior management.

9. Inventory & Material Coordination

• Coordinate billet/raw-material availability with stores and purchase teams.
• Monitor availability of rolls, guides, consumables and critical spares.
• Control material handling and minimize inventory-related production interruptions.

10. Team & Cross-Functional Coordination

• Coordinate with Maintenance, Quality, PPC, Stores, Purchase, Electrical, Instrumentation and Dispatch departments.
• Conduct daily production review meetings.
• Resolve production-related issues quickly.
• Ensure smooth shift-to-shift handover.

Key Skills Required

• Rod/wire rod rolling mill process knowledge
• Production planning and control
• Rolling mill operation
• Team and manpower management
• Quality management
• Preventive/breakdown maintenance coordination
• Cost reduction and productivity improvement
• Safety management
• KPI/MIS reporting
• Problem-solving and decision-making
• Knowledge of 5S, Kaizen, Lean Manufacturing and TPM