Plant Head – Recycled Polymer Manufacturing
Location: SIPCOT Industrial Park, Gummidipoondi, Chennai (Regular travel to Coimbatore Plant)
About JC Global Refineries Pvt. Ltd.
JC Global Refineries Pvt. Ltd. is a fast-growing manufacturer of recycled polymers and circular economy solutions. We manufacture premium recycled PP, HDPE, ABS, HIPS and engineering plastic compounds using advanced recycling technologies. We are building a world-class manufacturing organization driven by Operational Excellence, ESG, Digital Manufacturing and Industry 4.0.
We are looking for an experienced, hands-on Plant Head who can lead complete manufacturing operations, build high-performing teams, improve productivity and profitability, and establish a culture of operational excellence.
Position Summary
The Plant Head will have complete responsibility for the overall performance of the manufacturing plant, including Production, Maintenance, Quality, Utilities, Planning, EHS, Compliance, Cost, Delivery, Digital Manufacturing, Automation and Organizational Culture.
The role requires a strong manufacturing leader capable of driving productivity, efficiency, quality, people performance and continuous improvement while ensuring complete statutory and customer compliance.
ExperienceMandatory
- 15–25 years of experience in manufacturing.
- Minimum 8 years in Plant Head / Factory Head / Manufacturing Head / Operations Head role.
- Experience in Polymer, Plastic Recycling, Plastic Processing, Polymer Compounding, Petrochemical or Chemical Process Industry.
- Experience managing medium to large manufacturing plants.
EducationMandatory
- B.E./B.Tech – Mechanical / Chemical / Polymer / Production Engineering
Preferred
- MBA (Operations)
- Lean Manufacturing
- Six Sigma Green/Black Belt
- TPM Certification
- ISO Internal/Lead Auditor
Key Responsibilities1. Complete Plant Leadership
- Lead complete manufacturing operations with full ownership of Safety, Production, Quality, Cost, Delivery and People.
- Develop annual manufacturing strategy aligned with business objectives.
- Ensure uninterrupted plant operations through effective planning and execution.
- Build a disciplined, accountable and performance-driven manufacturing organization.
2. Production Excellence
- Achieve daily, weekly, monthly and annual production targets.
- Ensure On-Time-In-Full (OTIF) production and dispatch.
- Improve Overall Equipment Effectiveness (OEE).
- Increase plant capacity utilization and throughput.
- Improve machine utilization and manpower productivity.
- Eliminate production bottlenecks.
- Reduce manufacturing cycle time.
- Optimize shift planning and production scheduling.
- Continuously improve manufacturing efficiency and output.
3. Maintenance & Plant Reliability
Take complete ownership of maintenance and equipment reliability.
Responsible for:
- Preventive Maintenance
- Predictive Maintenance
- Breakdown Maintenance
- TPM Implementation
- Machine Availability
- MTBF & MTTR Improvement
- Spare Parts Planning
- Annual Shutdown Planning
- Equipment Reliability
- Utilities Management
- Extruder Maintenance
- Washing Line Maintenance
- Compressors
- Cooling Towers
- Chillers
- DG Sets
- Electrical Systems
- Mechanical Systems
Drive maximum machine uptime and minimize production losses due to equipment failure.
4. Plant Efficiency & Operational Excellence
Drive continuous improvement in:
- Overall Plant Efficiency
- OEE
- Capacity Utilization
- Machine Utilization
- Production per Shift
- Labour Productivity
- Material Yield
- Energy Efficiency
- Water Efficiency
- Asset Utilization
Implement:
- Lean Manufacturing
- TPM
- Six Sigma
- Kaizen
- 5S
- SMED
- Poka-Yoke
- Daily Management System
- Root Cause Analysis
- CAPA
5. Quality Excellence
Build a Zero Defect manufacturing culture.
Responsible for:
- Reject Reduction
- Rework Elimination
- Customer Complaint Reduction
- Product Consistency
- Process Standardization
- First Pass Yield Improvement
- Product Traceability
- Quality Systems Implementation
Ensure "Right First Time" manufacturing practices across the plant.
6. Environment, Health & Safety (EHS)
Develop a world-class safety culture.
Responsible for:
- Zero Accident Culture
- Behaviour Based Safety
- HIRA
- Permit to Work
- Incident Investigation
- Fire Safety
- Emergency Preparedness
- Contractor Safety
- PPE Compliance
- Waste Management
- Energy Conservation
- Water Conservation
Target:
- Zero Fatality
- Zero Lost Time Injury
- Zero Major Environmental Incident
7. Compliance & Governance
Ensure complete compliance with:
- Factories Act
- Labour Laws
- Pollution Control Board Requirements
- Fire & Safety Regulations
- ISO 9001
- ISO 14001
- ISO 45001
- ESG Requirements
- EPR Compliance
- ISCC PLUS
- Internal Audits
- Customer Audits
- Government Inspections
Maintain audit readiness throughout the year.
8. Automation & Digital Manufacturing
Lead digital transformation initiatives.
Implement and improve:
- ERP
- Manufacturing Execution System (MES)
- PLC & SCADA
- IoT Machine Monitoring
- Live Production Dashboards
- Digital SOPs
- Barcode & QR Code Traceability
- Paperless Manufacturing
- CMMS
- Predictive Analytics
- AI-based Production Monitoring
- Utility Monitoring Systems
Continuously identify automation opportunities to improve productivity and reduce manual intervention.
9. Data Management & MIS
Ensure complete accuracy of:
- Production MIS
- Shift Reports
- OEE Reports
- Downtime Reports
- Breakdown Reports
- Inventory Reports
- Utility Reports
- Energy Reports
- KPI Dashboards
- EHS Dashboard
- ESG Dashboard
- Management Reports
Drive data-based decision-making across all departments.
10. KPI & Performance Management
Develop and implement KPIs for every department and employee.
Ensure:
- Daily KPI Reviews
- Weekly Operational Reviews
- Monthly Performance Reviews
- Department Scorecards
- Individual KRAs
- Performance Improvement Plans
- Accountability Reviews
Build a culture where every employee is measured on performance.
11. Cost Optimization
Drive continuous reduction in:
- Manufacturing Cost
- Power Cost
- Water Cost
- Maintenance Cost
- Labour Cost
- Scrap
- Rework
- Consumables
- Packaging Cost
Improve EBITDA through operational excellence.
12. Organizational Culture & Leadership
Develop a high-performance manufacturing culture based on:
- Accountability
- Ownership
- Discipline
- Integrity
- Teamwork
- Continuous Learning
- Respect
- Innovation
- Employee Development
- Performance Excellence
Lead by example and ensure organizational values are practiced from senior management to contract workforce.
13. People Development
- Develop department heads and supervisors.
- Build succession plans for key positions.
- Improve employee competency through structured training.
- Develop skill matrices and leadership pipelines.
- Improve employee engagement and retention.
Key Performance Indicators (KPIs)
- Production Target Achievement
- OTIF Production & Dispatch
- OEE Improvement
- Plant Efficiency
- Capacity Utilization
- Machine Availability
- MTBF / MTTR
- Reject Reduction
- First Pass Yield
- Customer Complaint Reduction
- Manufacturing Cost per MT
- Energy Consumption per MT
- Water Consumption per MT
- Preventive Maintenance Compliance
- Zero LTI
- Zero Statutory Non-Compliance
- ISO / ESG / EPR Compliance
- Automation Projects Implemented
- ERP Data Accuracy
- KPI Achievement Across Departments
- Employee Productivity
- Skill Matrix Completion
- Continuous Improvement Projects
- EBITDA Improvement
Desired Competencies
- Strong shop-floor leadership.
- Excellent knowledge of polymer manufacturing and recycling processes.
- Expertise in maintenance and equipment reliability.
- Proven track record in improving plant efficiency, OEE and productivity.
- Strong understanding of Lean Manufacturing, TPM and Six Sigma.
- Experience implementing ERP, MES and digital manufacturing systems.
- Excellent analytical, planning and problem-solving skills.
- Strong people management and coaching ability.
- High integrity, discipline and accountability.
- Willing to work beyond normal business hours whenever production demands.
- Willing to relocate and establish a long-term base with family near the plant for sustained organizational commitment.
- Willing to travel regularly between the Chennai and Coimbatore manufacturing facilities.
Pay: From ₹60,000.00 per month
Work Location: In person
