Company Description
Bhatia Alloy Forgings Private Limited, established in 1996, is a leading provider of integrated solutions for manufacturing aluminum and other lightweight materials. Committed to sustainability, the company focuses on creating high-strength, lightweight, and recyclable products to improve efficiency and safety while reducing environmental impact. With state-of-the-art facilities and advanced processes such as hot and cold forging, heat treatment,Machining, surface finishing, and testing, Bhatia Alloy caters to the evolving needs of OEMs. The company's mission is to enhance vehicle safety, comfort, and environmental compliance. Headquartered in India, they are driven by innovation and sustainability to help clients achieve scalable business growth.
Position Title: Plant Head- Aluminium Forging Plant 1
Department: Operations
Reports to: CEO
Location: Plant- 1 (Sector-24, Faridabad)
Qualification & Experience: Dip./ BE. / B.Tech. Mechanical
Experience: 15 Yrs.+
Grade: D1
About the Role:
The Plant Operations Department plays a pivotal role in managing and overseeing the day-to-day operations of the Aluminium Forging Plant. It encompasses various functions and responsibilities that are essential for the efficient and effective functioning of the manufacturing process. The department's primary objective is to ensure the production of high-quality forged aluminum products in a safe and cost-effective manner while meeting customer demands and industry standards.
As a key member of the senior management team, you will play a pivotal role in driving the plant's overall success and growth by fostering a culture of continuous improvement by periodic auditing, innovation, and operational excellence.
Key Responsibilities:
Strategic Planning:
- Develop and implement the plant's strategic plans, aligning them with the overall organizational goals and objectives.
- Set performance targets and KPIs for various operational functions, ensuring alignment with company-wide targets.
Production Management:
- Oversee and coordinate the plant's production activities, ensuring efficient utilization of resources and adherence to production schedules.
- Monitor production performance to identify areas of improvement and optimize manufacturing processes.
OTIF :
- Ensure achievement of On Time In Full (OTIF) delivery targets by aligning production planning, inventory management, and dispatch activities. The Plant Head must proactively identify bottlenecks, coordinate cross-functional teams, and implement process improvements to consistently meet internal & external customer delivery commitments without compromising on quality.
PPC :
- Production, Planning & Control, Creating Daily, Weekly & Monthly Plans to meet Customer requirements.
Quality Control and Assurance:
- Establish and maintain robust quality control procedures to ensure that all forged aluminum products meet required specifications and industry standards.
- Collaborate with the Quality Assurance team to drive continuous improvement in product quality and customer satisfaction.
Analysis & Audits:
- Ensure timely execution and oversight of all plant-level audits and operational analysis, including production, quality, safety, maintenance, and compliance. He must identify gaps, drive root cause analysis, implement corrective actions, and ensure adherence to internal and external audit requirements.
Health, Safety, and Environmental Compliance:
- Lead and promote a strong safety culture within the plant, ensuring compliance with all relevant health and safety regulations.
- Implement and monitor environmentally sustainable practices in line with industry standards and legal requirements.
Equipment Maintenance and Engineering:
- Work closely with the maintenance and engineering teams to ensure optimal functioning of plant machinery and equipment, reducing downtime and maximizing efficiency.
Process Optimization and Continuous Improvement:
- Champion Lean Manufacturing, Six Sigma, or other process improvement methodologies to drive operational efficiency and eliminate waste.
- Lead cross-functional teams to identify process bottlenecks and implement solutions for continuous improvement.
Budget Management:
- Collaborate with the executive team to establish annual budgets for the plant's operations and monitor expenditures to achieve cost targets.
Talent Development and Team Leadership:
- Build and lead a high-performing operations team, providing guidance, coaching, and professional development opportunities.
- Foster a positive and collaborative work environment that promotes employee engagement and retention.
Stakeholder Management:
- Collaborate with other departments, such as sales, marketing, and procurement, to ensure smooth interdepartmental coordination and support overall business objectives.
Reporting and Analysis:
- Prepare regular reports on plant performance, operational efficiency, and other relevant metrics for presentation to the executive team and stakeholders.
Qualifications and Requirements:
- Bachelor's degree in Mechanical Engineering, Industrial Engineering, Business Administration, or a related field. Advanced degree preferred.
- Extensive experience (typically 10+ years) in a senior leadership role within an aluminum forging plant or similar heavy manufacturing environment Steel Forging environment .
- In-depth knowledge of aluminum /Steel forging processes, metallurgy, and industry best practices.
- Demonstrated track record of successful strategic planning, operational management, and process optimization.
- Proven leadership skills with the ability to inspire and motivate teams to achieve goals and objectives.
- Strong analytical and problem-solving skills, with a data-driven approach to decision-making.
- Familiarity with health, safety, and environmental regulations related to manufacturing operations.
- Excellent communication and interpersonal abilities, capable of effectively engaging with stakeholders at all levels of the organization.
As the Plant Head- Forging, your role is critical to New Product Development (NPD), Design & Quality, and Process Improvement. Let's explore the specific roles you would play in each of these areas as well:
New Product Development (NPD):
- Collaboration with R&D: You would collaborate with the Research and Development (R&D) team to understand upcoming product designs, specifications, and customer requirements. Your expertise in aluminum forging processes will be essential in assessing the feasibility of new products from a manufacturing perspective.
- Process Design and Feasibility: You will be responsible for evaluating the manufacturability of new product designs. By working closely with the engineering and design teams, you can provide valuable insights to ensure that the proposed products can be forged efficiently while meeting quality standards.
- Capacity Planning: As new products are introduced, you will need to assess the impact on production capacity and plan for any necessary adjustments in resources, machinery, and workforce to accommodate the increased workload.
- Cross-Functional Coordination: NPD involves multiple departments, including design, engineering, production, and quality assurance. You will play a crucial role in facilitating effective communication and collaboration among these teams to ensure successful product launches.
Design & Quality:
- Quality Management Systems: You will be responsible for implementing and maintaining robust quality management systems throughout the manufacturing process. This includes developing quality control procedures, conducting inspections, and ensuring compliance with relevant quality standards.
- Design Validation: As a subject matter expert in aluminum forging, you will review product designs and specifications to ensure they align with the plant's capabilities and are optimized for manufacturing efficiency without compromising product quality.
- Root Cause Analysis: In cases where quality issues arise, you will lead or participate in root cause analysis investigations to identify the underlying reasons and implement corrective actions to prevent recurrence.
- Supplier Quality Management: You may be involved in assessing and managing the quality of materials and components supplied to the plant. Collaborating with the procurement team, you can ensure that suppliers meet quality standards and contribute to the overall product quality.
Risk Management:
- Lean Manufacturing & Six Sigma: You will champion the implementation of Lean Manufacturing and Six Sigma methodologies to drive process improvements, reduce waste, and increase efficiency throughout the production process.
- Data Analysis: As the Plant Head, you will utilize data analysis to identify bottlenecks, inefficiencies, and opportunities for improvement in various stages of the forging process. Data-driven decisions will help in optimizing production and resource allocation.
- Continuous Improvement Culture: Instilling a culture of continuous improvement within the plant is essential. By encouraging and supporting employees to identify and propose process improvements, you can foster an environment that continually seeks to enhance operations.
- Automation & Technology: You will be involved in assessing the potential of automation and advanced technologies in aluminum forging processes to improve productivity and overall manufacturing capabilities.
Overall, your expertise and leadership in NPD, Design & Quality, and Process Improvement will be instrumental in driving innovation, ensuring product excellence, and optimizing the overall manufacturing efficiency of the Aluminium Forging Plant.
