Plant Head (AAC Plant Production In-Charge)

AK Construction Materials (brand: Artha AAC Blocks) is hiring a Production In-Charge to run its AAC block plant in Nellore, Andhra Pradesh, and own production output, quality and cost.

The plant has an installed capacity of about 50 m³ per day (two 25 m³ cycles), with its own boiler, autoclaves, cutting line and material-handling equipment. The role starts with a controlled restart: trial cycles, then validation, then stable production of 1,100–1,300 saleable m³ per month.

• Location: Nellore, Andhra Pradesh (on-site)
• Reports to: Managing Director / Promoter
• Type: Full-time, permanent, after a 3-month probation
  

Key responsibilities

Production

• Run the full process: batching, mixing, pouring, rising, green cake handling, cutting, autoclaving, de-moulding and stacking.
• Plan daily production against confirmed orders, not for stock.
• Move the plant from one cycle a day to two, reliably.
• Coordinate with the boiler team on steam availability and autoclave cycles.

Quality

• Keep blocks within BIS limits for density, compressive strength and dimensions.
• Run regular lab tests and keep test records, supporting BIS, ISO and ZED requirements.
• Investigate every rejection, find the cause and fix it.

Process control

• Write and maintain standard recipes and process parameters.
• Keep fly ash content above 50% in every batch and record it on the batch sheet.
• Reduce cement, lime, aluminium powder, power and fuel use per m³.

Maintenance

• Run a preventive maintenance schedule for moulds, cutting machine, boiler, autoclaves and handling equipment.
• Keep a list of critical spares and request purchases with justification.
• Prevent damage during handling and loading.

People and safety

• Lead the in-house production team and contract labour; plan shifts and attendance.
• Train operators so that no part of the process depends on one person.
• Enforce safety for boiler, autoclave, forklift and electrical work.

Reporting

• Submit a daily production report: output, rejection, consumption and breakdowns.
• Submit a monthly report on cost per saleable m³ and progress against targets.

Performance targets

The role is measured on these numbers. The monthly bonus is tied to the first three.

Measure

Steady-state target

Saleable output

5 consecutive successful 25 m³ cycles

1,100–1,300 m³ per month

Rejection

5% or less

3% or less

Cost per saleable m³ (all-in production)

1,950 or less

1,900 or less

Cycles per day

1, stable

2, stable

Unplanned breakdowns

No breakdown stopping a validation cycle

Fewer than 2 per month

Quality

Density and strength within BIS limits

Within BIS limits on every test

Authority and reporting

The Production In-Charge has full authority over production and is accountable for its results. Sales, purchasing, finance and customers stay with management.

The Production In-Charge decides:

• daily production plan, shifts and staff allocation within the approved team;
• process parameters and recipe adjustments, within the documented limits;
• stopping production for a quality or safety problem;
• assigning and supervising contract labour.

Needs management approval:

• any spending above an agreed limit per item;
• hiring or removing core team members;
• changes to the approved recipe outside documented limits;
• production plans beyond confirmed orders.

Team reporting to this role: Senior AAC Operator, Batching/Mixing Operator, Boiler Operators, Maintenance Fitter, QC Technician, Forklift Operator, and contract production labour.

Requirements

Must have

• 5+ years in AAC block manufacturing, including at least 2–3 years as shift in-charge, assistant production manager or production head.
• Hands-on experience of the full process: batching, rising, cutting, autoclaving and boiler coordination.
• Has run a plant at 1,000+ m³ per month or two cycles a day.
• Can diagnose common problems: mould leakage, cracks, density variation, collapse during rising, cutting defects.
• Working knowledge of BIS requirements for AAC blocks and basic lab testing.
• Experience leading operators and contract labour.
• Comfortable with daily records, production reports and basic cost calculations.

Good to have

• Experience with fly ash-based recipes and reducing cement or aluminium powder use.
• Boiler or autoclave safety training.
• Diploma or degree in mechanical, chemical or civil engineering.
• Languages: Telugu and/or Tamil, with working Hindi or English.

What we offer

• Fixed monthly salary, based on experience.
• Monthly performance bonus linked to saleable output, rejection rate and cost per m³.
• Full authority over production, with a clear split of responsibilities with management.