Plant Manager / Head of Manufacturing – Corrugated Packaging (Automatic Plant)

Job Description:

Location:

Waluj MIDC, Chhatrapati Sambhaji Nagar

Reporting To:

Director / Managing Director

Role Summary:

The Plant Manager will be responsible for complete ownership and management of the corrugated box manufacturing unit. This includes overseeing production, quality, maintenance, raw material planning, customer coordination, manpower management, and overall plant profitability.

The role requires a hands-on leader who can independently drive operations, implement systems, and ensure high efficiency, quality standards, and customer satisfaction.

Key Responsibilities (KRAs):

1. End-to-End Plant Operations

• Oversee complete plant operations including production, quality, maintenance, stores, dispatch, and coordination with accounts.
• Ensure seamless inter-departmental coordination.
• Drive overall plant performance aligned with business goals.

2. Production Planning & Execution

• Plan and execute daily, weekly, and monthly production schedules.
• Ensure optimum capacity utilization and timely delivery.
• Monitor production output and adherence to targets.

3. Raw Material & Inventory Management

• Manage procurement and usage of raw materials such as kraft paper, adhesives, and consumables.
• Implement inventory control systems to reduce wastage and optimize working capital.
• Coordinate with purchase, stores, and accounts teams.

4. Quality Control & Continuous Improvement

• Ensure adherence to quality standards and customer specifications.
• Monitor key parameters like GSM, BF, ECT, and bursting strength.
• Drive CAPA (Corrective & Preventive Actions) and continuous improvement initiatives.
• Aim for near-zero customer complaints.

5. Customer Coordination & Product Development

• Engage with customers for technical discussions and issue resolution.
• Support sales team in feasibility studies and product development.
• Ensure timely delivery and high customer satisfaction.

6. Cost Control & Profitability

• Monitor conversion costs, wastage, and operational expenses.
• Analyze production reports and cost variances.
• Drive initiatives to improve plant profitability.

7. Team Leadership & Manpower Management

• Lead recruitment, training, and development of plant workforce.
• Build a strong leadership pipeline.
• Maintain a performance-driven and disciplined work culture.

8. Maintenance & Machine Efficiency

• Ensure effective preventive and predictive maintenance systems.
• Minimize machine downtime and improve OEE (Overall Equipment Effectiveness).
• Maintain optimal machine performance.

9. Safety, Compliance & Systems

• Ensure compliance with safety norms and statutory requirements.
• Implement and maintain 5S, SOPs, and best practices.
• Identify and mitigate operational and safety risks.

10. Reporting & Decision Making

• Analyze production, quality, and cost reports.
• Provide regular performance updates to management.
• Take data-driven decisions to improve efficiency and resolve issues.

Key Performance Indicators (KPIs):

• Production vs Plan (%)
• Capacity Utilization & OEE
• Wastage Reduction (%)
• Customer Complaints (Target: Near Zero)
• On-Time Delivery (%)
• Cost per Unit / Conversion Cost
• Machine Downtime
• Inventory Turnover
• Employee Productivity & Retention

Qualifications:

• B.E. / Diploma in Mechanical / Production / Industrial Engineering
• MBA (Operations) – Preferred

Experience:

• 10–15+ years in the corrugated packaging industry

Key Skills:

• Strong techno-commercial and P&L understanding
• Expertise in corrugation processes and automatic machinery
• Leadership and team management skills
• Analytical and problem-solving ability
• Strong customer handling and coordination skills

Expectation from the Role:

• Ability to independently manage and run the entire plant
• Strong ownership mindset with business-oriented thinking
• Capability to build systems and reduce dependency on promoters
• Focus on operational excellence and profitability