Operation /Plant -Head in Tirupati (only For Battery& Lead Recycling)

Key Responsibilities

Operational Excellence

• Ensure Achievement of Business Plan from Operation side of Plant, keep regular track of production and costs and take corrective actions whenever there is any deviation to ensure all targets are achieved as defined in Business Plan
• Work with Plant Head and production teams and do periodic materials planning and ensure there is no loss of production and man-days due to unavailability of RML and other materials supply
• Strictly monitor chemical usage and ensure that the usage is as per standards
• Develop and manage internal & external processes and functions to support the Plant, without losing sight of the imperative to continuous growth and scaling the organization in an aggressive manner for next levels of performance
• Keep control on Operative cost of Plant to ensure better gross margin and profitability through enhancement of processes, cost optimization projects and innovation
• Building and execution of an effective supply chain management model to sustain tenacity of aggressive business growth requirement of Plant
• Implement robust Production Planning and Control to ensure sustainable production for continuous supply of Lead Alloys as per the sales indent, customer demand and market trends and also assure there is no revenue loss due to the production in Plant
• Drive Quality standards and measures to improve the quality of lead alloys manufacturing system/process in plant and ensure we are following the best practices used in global lead manufacturing standards

Productivity Management

• Develop production plans based on sales orders and ensuring accomplishment of targets as per business plan
• Reviewing daily production of each section (BBSU, Smelting and Refining) and taking corrective measures wherever necessary to ensure timely accomplishment of production targets
• Checking Actual production against company standards and taking corrective actions where ever and whenever required
• Close monitoring on fuel and consumables to optimize cost of production and ensure cost of production is not exceeding than the predefined standards and there is no compromise on desired quality standards.
• Drive continuous improvement and cost reduction projects: mentoring & enabling execution of Lean manufacturing and Kaizen projects for elimination of business irritants and non-value added process

Industrial Engineering

• Regular analysis on available machineries in BBSU, Rotaries in smelting and pots in refining and if required recommend for new machines/equipment’s and renovation and modification of existing machines/equipment’s.
• Define production processes stage wise and do lay out designing of plant, to ensure optimum production with less production cycle time and manpower requirements
• Define Preventive maintenance plan and ensure rigorously plan has been adhered with proper MIS on health of all machineries
• Organizing the repair and routine maintenance of production equipment and ensure there is no loss of Production because of Equipment or Machine Breakdown
• Guide and help project and maintenance team to install and commission new machines and equipment’s as per the lay out, design and functional requirements

Manpower Optimization

• Work on daily, monthly and yearly workforce planning and recommend required quality manpower
• Conduct manpower cost analysis and ensure manpower cost is under control
• Close Monitoring of Casual and Contractual Work Force numbers as per production norms
• Tracking of manpower numbers, sections and segment wise and do optimization of existing manpower before recommending change

BBSU and Manual cutting

• Ensure sufficient stock of scrap battery availability for continues production as per production plan
• Ensure material is stacked and used separately according to its type and proper calculation is done separately for each type
• Ensure BBSU production and Manual cutting production is as per plan
• Ensure the recovery (plate, grid, fine grid and paste) and moisture in paste is as per standards
• Ensure material input to the BBSU section is matching with total output (plastic, plate, grid, fine grid and paste)
• Ensure all the log sheets are properly filled and signed by the concerned persons
• Ensure preventive maintenance is scheduled is made and adhered
• Ensure minimum breakdown of BBSU and ensure breakdown time is recorded properly

Smelting

• Ensure sufficient stock of lead material (plate, grid, fine grid and paste) and charging material (charcoal, soda ash, mill scale, cast iron, lime stone etc) availability for continues production in rotaries as per production plan
• Ensure rotary production is as per plan
• Ensure material and fuel consumption is as per standards
• Ensure the recovery from the rotaries is as per standards and in case there is any deviation try to find out reasons and take corrective actions
• Ensure material input (lead material from BBSU section & manual cutting and charging material) in smelting section matches the output (Block, slag and flue dust)
• Ensure Batch and cycle times are as per standards
• Ensure slag is segregated and stored properly and slag with more than standard lead content is recycled in rotary
• Ensure all the log sheets are properly filled and signed by the concerned persons
• Ensure preventive maintenance is scheduled is made and adhered
• Ensure minimum breakdown of rotaries and ensure breakdown time is recorded properly

Refining and Packing

• Ensure sufficient stock of Raw Material (RML Block from Rotary, RML ingots and Master Metal ingots) and critical chemicals (Arsenic, Selenium, Silver etc.) is always above minimum inventory level
• Ensure refining production is as per plan
• Ensure material and fuel consumption is as per standards
• Ensure the recovery from the refining is as per standards and in case there is any deviation try to find out reasons and take corrective actions
• Ensure material input (RML Block from Rotary, RML ingots and Master Metal ingots) in smelting section matches the output (Finished Good, Bad Ingots, skimming, scrap etc)
• Ensure cycle times are as per standards
• Ensure all the log sheets are properly filled and signed by the concerned persons
• Ensure minimum breakdown in refining section and ensure breakdown time is recorded properly
• Ensure Packing is done as per company standards and as specified by the customer
• Ensure packed material is available as per dispatch plan
• Ensure Packing is done in time and there is minimum inventory of unpacked finished goods

Production Quality

• Implement different verticals of Manufacturing Excellence, including vertical for technical quality, Environ Management (EHS), TQM and Production Process Management
• Execute production quality standards, create awareness and set periodic target to improve and monitor the outcome
• All quality standards are adhered on production floor in consultations with Quality department and there is no NC in internal and external audits

Environment Health & Safety

• Ensure all safety equipment are placed as per the standards and statutory compliances
• All Health, Safety and environment related certification have been completed and there is no NC during any internal or external audits.
• In coordination with Plant HR and Admin conduct regular awareness session to educate production floor workers and relevant staffs to avoid any accidents due to negligence and lack of awareness
• Ensure sufficient availability of personal protection equipment (PPE) in plant and ensure all the people on production are using them (especially mask, helmet and safety shoes)
• Inspect and evaluate the equipment and processes related to pollution/environment in working areas to ensure compliance with government safety regulations and industry standards.
• Ensure all compliances of Pollution Control Board are met properly and there is no NC found in Internal or external Audits and there are no complaints.

MR Management

• Ensure proper Implementation of ISO Standards in the Plant
• Ensuring proper preparation of documents for ISO Audits and other Certifications (including fire and safety)
• Ensuring awareness and training sessions of ISO standards and other Certifications are done regularly among employees
• Ensuring the compliance of all the functions as per the ISO standard
• Conducting Internal Audits and making nonconformity reports
• Measuring & Monitoring the process performance
• Initiate necessary corrective and preventive action
• Review of Quality policy periodically Time to time review of all the functions, to check the effective implementation of Quality Management system.
• Ensuring removal of open points mentioned in Corrective Actions Required list by Auditors during any Audit

People Management

• Manage workforce and build harmonious working environment on production floor for better productivity
• Review and measures individual performance on regular basis and reward good performer and initiate performance improvement plan for below average performer.
• Drive Kaizen, 5’s and other innovative system to improve performance of individuals.
• Identify skills set and skill gap of individual and impart regular coaching and training to cope with standard performance benchmark and strive to take each individual performance at next level