Plant Head – Manufacturing & Factory Operations

About the Role

Celestix Industries is establishing a large-scale, greenfield manufacturing campus in Falna, Rajasthan, with multiple factories dedicated to electrical components, copper processing, precision metal fabrication and industrial manufacturing.

We are hiring an experienced Plant Head / Plant Manager to lead the establishment, commissioning and overall manufacturing operations of this new industrial campus.

This senior leadership position is suitable for an experienced Factory Manager, Production Head or Manufacturing Head who has successfully managed complex manufacturing operations and preferably participated in setting up a new factory or expanding an existing manufacturing facility.

The selected Plant Head will initially be responsible for greenfield plant setup, factory infrastructure coordination, machinery installation, equipment commissioning, production line development, manpower planning, operational systems and manufacturing readiness.

Once the manufacturing facilities become operational, the Plant Head will assume responsibility for factory-wide production performance, department leadership, production planning, manufacturing quality, machine utilization, cost control, delivery commitments, safety and continuous improvement.

Our manufacturing operations are expected to include:

• Wiring harness and cable assembly manufacturing
• Copper busbar manufacturing and fabrication
• CNC sheet metal laser cutting, bending and forming
• Structural steel fabrication and welding
• Precision metal components and assemblies
• Associated manufacturing, inspection, testing and finishing processes

The most important requirement is proven experience in plant management, manufacturing leadership, factory setup and the ability to independently establish and operate a high-performance manufacturing organization.

We are not looking for someone whose experience is limited to desk-based production reporting. The ideal candidate must be a hands-on manufacturing leader who can independently resolve operational problems, manage department heads and establish strong production systems.

Key Responsibilities

1. Greenfield Plant Setup, Factory Development & Commissioning

The Plant Head will play a central role in establishing the new manufacturing campus from the ground up.

Responsibilities include:

• Develop a phased plan for establishing manufacturing operations.
• Coordinate factory setup activities according to approved project schedules.
• Review manufacturing infrastructure requirements for different production divisions.
• Participate in planning factory layouts, production flow and machine positioning.
• Coordinate with Civil, Electrical, Mechanical, Maintenance and Project teams.
• Identify utility requirements, including electrical power, compressed air, ventilation and material handling.
• Review machinery installation and equipment commissioning schedules.
• Coordinate production readiness with equipment suppliers and contractors.
• Ensure tools, fixtures, consumables and inspection equipment are available before production.
• Monitor commissioning trials and initial manufacturing activities.
• Identify delays, technical problems and operational risks.
• Escalate project deviations and coordinate corrective actions.
• Establish production systems, reporting procedures and departmental responsibilities.
• Support transition from factory construction to regular manufacturing operations.

The Plant Head will be accountable for overall manufacturing readiness while coordinating with qualified specialists responsible for civil, structural, electrical and other engineering disciplines.

2. Plant Management & Multi-Factory Operations

As the overall Plant Manager, the selected candidate will lead manufacturing operations across multiple production divisions.

Responsibilities include:

• Establish factory-wide manufacturing objectives and performance targets.
• Manage departmental Production Managers and operational teams.
• Coordinate production schedules across manufacturing divisions.
• Monitor daily, weekly and monthly production performance.
• Maintain effective utilization of manpower, machines, materials and manufacturing methods.
• Review production bottlenecks and implement corrective action.
• Ensure manufacturing activities follow approved processes and quality requirements.
• Maintain coordination between Production, Quality, Maintenance, PPC, Stores and Dispatch.
• Establish clear performance accountability.
• Monitor productivity, manufacturing costs and delivery performance.
• Develop systems to support future factory expansion.

The candidate should have demonstrated experience managing complex manufacturing operations involving multiple production processes.

3. Manufacturing Operations & Production Leadership

The Plant Head will provide strategic and operational oversight of daily manufacturing activities.

Responsibilities include:

• Review production plans and manufacturing priorities.
• Monitor actual production against approved schedules.
• Ensure production resources are allocated effectively.
• Coordinate with Production Managers to address manpower and equipment limitations.
• Review machine availability, production efficiency and process performance.
• Ensure production delays are communicated and resolved promptly.
• Improve coordination between manufacturing departments.
• Establish procedures for production escalation and problem resolution.
• Support process standardization and repeatable production performance.
• Ensure customer delivery commitments are supported by manufacturing capacity.

4. Wiring Harness & Cable Assembly Manufacturing Oversight

Provide management oversight of the wiring harness manufacturing division.

The candidate should understand the general manufacturing requirements of:

• Wire cutting and stripping
• Terminal crimping
• Connector assembly
• Cable assembly
• Soldering and splicing
• Ultrasonic welding
• Harness routing and taping
• Continuity and electrical testing
• In-process inspection
• Final testing and packing

Responsibilities include:

• Review production capacity and equipment requirements.
• Monitor output, quality and production efficiency.
• Coordinate resources with the Wiring Harness Production Manager.
• Support manpower planning and operator training.
• Ensure approved production processes are followed.
• Review rejection, rework and testing bottlenecks.
• Support improvements in manufacturing productivity.
• Ensure the production division can scale according to customer requirements.

Direct wiring harness manufacturing experience is advantageous but not mandatory for candidates with strong multi-process manufacturing leadership.

5. Copper Busbar Manufacturing & Copper Material Control

Oversee the establishment and operational performance of the copper busbar manufacturing division.

Processes may include:

• Copper cutting and shearing
• CNC busbar punching
• Drilling and machining
• Copper bending and forming
• Deburring and finishing
• Surface preparation
• Plating and insulation coordination
• Final inspection and packing

Responsibilities include:

• Coordinate production planning and manufacturing capacity.
• Review machinery and tooling requirements.
• Monitor raw copper material utilization.
• Establish copper scrap-control and material reconciliation procedures.
• Ensure proper segregation of reusable copper offcuts and scrap.
• Monitor manufacturing yield and material losses.
• Review dimensional quality and manufacturing rejection.
• Coordinate process improvements and productivity initiatives.
• Maintain accountability for high-value copper inventory and production consumption.

Because copper is a high-value raw material, the Plant Head must place strong emphasis on material yield, inventory accuracy, scrap reconciliation and manufacturing cost control.

6. Sheet Metal Fabrication & Structural Welding Operations

Oversee the sheet metal fabrication and structural manufacturing divisions.

Manufacturing processes may include:

• CNC fiber laser cutting
• Sheet metal nesting
• CNC press brake bending
• Punching and forming
• MIG/MAG welding
• ARC/Stick welding
• TIG welding where applicable
• Structural steel fabrication
• Grinding and deburring
• Fabricated component assembly
• Dimensional inspection

Responsibilities include:

• Monitor production capacity and machine utilization.
• Ensure efficient sheet metal nesting and raw material utilization.
• Review manufacturing output, cycle times and production bottlenecks.
• Coordinate fabrication schedules and downstream processes.
• Monitor dimensional quality, welding quality and material wastage.
• Support improvements in production efficiency and process standardization.
• Ensure adequate tooling, fixtures and production resources are available.

7. Manufacturing Machinery Selection, Installation & Commissioning

• Participate in technical evaluation and selection of production machinery.
• Review equipment capacities and manufacturing requirements.
• Coordinate with suppliers regarding machine specifications and commissioning.
• Support machine installation and factory acceptance activities.
• Ensure appropriate utilities and installation infrastructure are available.
• Coordinate initial machine trials and process validation.
• Monitor equipment-related commissioning issues.
• Ensure technical documents and operator training are completed.
• Review tooling, fixtures and inspection requirements.
• Support machine capacity improvements and future equipment investments.

The Plant Head should understand manufacturing equipment sufficiently to identify unsuitable machine specifications, capacity limitations and operational risks.

8. Heavy Material Handling, EOT Cranes & Industrial Infrastructure

The manufacturing campus will require appropriate systems for handling heavy raw materials and fabricated components.

Responsibilities include:

• Coordinate industrial material-handling requirements.
• Review production needs involving EOT cranes and other lifting equipment.
• Ensure safe material movement and handling practices.
• Coordinate operational readiness of crane and lifting equipment.
• Ensure trained and authorized employees perform lifting operations.
• Monitor lifting equipment maintenance coordination.
• Establish suitable material movement procedures across the campus.
• Identify bottlenecks in material handling and transportation.
• Support safe handling of large or heavy fabricated components.

Structural design, crane certification and specialist lifting engineering will remain the responsibility of qualified professionals.

9. Production Planning, Scheduling & Delivery Performance

• Establish effective production planning and control systems.
• Review customer demand, manufacturing capacity and delivery priorities.
• Coordinate factory-wise production schedules.
• Monitor raw material and component availability.
• Ensure proper work-order execution and WIP control.
• Review bottlenecks affecting production or dispatch.
• Coordinate with PPC, Procurement, Stores, Quality and Production teams.
• Establish production recovery plans where required.
• Monitor on-time delivery performance.
• Ensure production schedules are realistic and aligned with available resources.

10. Manufacturing Quality, Process Control & Customer Requirements

• Establish a quality-focused manufacturing environment.
• Coordinate implementation and maintenance of quality management systems.
• Ensure approved drawings, specifications and procedures are followed.
• Review incoming, in-process and final inspection processes.
• Monitor production rejection, rework and customer complaints.
• Participate in root cause analysis of major quality incidents.
• Ensure timely corrective and preventive actions.
• Support customer audits, inspections and manufacturing approvals.
• Maintain appropriate product identification and traceability.
• Ensure departments focus on defect prevention and consistent workmanship.

Working knowledge of ISO 9001 and relevant industrial manufacturing quality practices is preferred.

11. Manufacturing Manpower Planning & Leadership

• Develop staffing plans for manufacturing departments.
• Identify requirements for Production Managers, engineers, supervisors, technicians and operators.
• Participate in recruitment of key manufacturing personnel.
• Establish departmental organizational structures and reporting relationships.
• Monitor manpower availability and productivity.
• Coordinate workforce recruitment and training with HR.
• Develop department managers and supervisors.
• Establish performance accountability and review systems.
• Support operator training and skill development.
• Ensure production departments are adequately staffed for commissioning and ramp-up.

The successful candidate must be capable of establishing a disciplined workforce and developing strong departmental leadership.

12. HR, Industrial Relations & Factory Administration Coordination

• Work with HR and Administration to support smooth factory operations.
• Coordinate manpower requirements, shift structures and staffing priorities.
• Support positive industrial and employee relations.
• Maintain manufacturing discipline and workplace accountability.
• Coordinate with HR regarding absenteeism and workforce availability.
• Support employee development and training requirements.
• Review contractor workforce performance where relevant.
• Coordinate operational needs involving security, transportation, canteen and factory services.
• Support compliance with applicable employment and workplace requirements.

HR, payroll, statutory employee records and administrative services will remain under their respective functions.

13. Plant Maintenance, Engineering & Utilities

• Oversee maintenance planning and equipment reliability through the Maintenance Manager.
• Establish preventive and corrective maintenance expectations.
• Monitor major breakdowns and recurring machine failures.
• Review machine availability and downtime.
• Ensure critical spares and consumables are planned.
• Coordinate operational requirements for electrical distribution, compressors and industrial utilities.
• Support technical troubleshooting and equipment improvements.
• Monitor maintenance performance and corrective action.
• Ensure factory operations have reliable equipment and utilities.

14. Manufacturing Budgeting, Cost Control & Operational Efficiency

• Prepare and monitor manufacturing operating budgets.
• Review production cost drivers and resource utilization.
• Monitor labour productivity and overtime costs.
• Control raw material wastage and production losses.
• Review copper yield and sheet metal utilization.
• Monitor manufacturing consumables and tooling costs.
• Identify opportunities to reduce rejection and rework.
• Support evaluation of equipment investments and manufacturing improvements.
• Coordinate operational cost reviews with Finance.
• Develop measurable productivity and cost-reduction initiatives.

The Plant Head must understand how production efficiency, material utilization and manufacturing quality influence factory profitability.

15. ERP, Manufacturing Systems & Inventory Control

• Ensure accurate manufacturing records are maintained in ERP or approved systems.
• Establish production reporting procedures across departments.
• Monitor raw material consumption and WIP transactions.
• Ensure finished-goods production reporting is accurate.
• Review inventory accuracy and manufacturing traceability.
• Coordinate BOM, routing and work-order system requirements.
• Support implementation of digital manufacturing processes.
• Improve reporting transparency and accountability.
• Coordinate with IT and ERP teams to resolve manufacturing data issues.

16. Factory Performance Reporting & KPIs

Develop and review key performance indicators, including:

• Planned versus actual production
• Capacity utilization
• Machine availability and OEE
• On-time delivery
• First-pass yield
• Rejection and rework
• Copper material utilization
• Copper scrap and stock reconciliation
• Sheet metal material yield
• Labour productivity
• Manufacturing cost
• Production lead time
• Work-in-progress
• Inventory accuracy
• Equipment downtime
• Safety performance
• Commissioning milestones

Prepare regular factory performance reports for management and implement corrective actions where targets are not achieved.

17. Lean Manufacturing & Continuous Improvement

• Implement Lean Manufacturing principles and practical process improvements.
• Establish standardized work practices.
• Promote 5S and visual management systems.
• Improve production flow and reduce bottlenecks.
• Reduce unnecessary material handling and waiting time.
• Support Kaizen and root cause analysis.
• Improve machine utilization and changeover times.
• Encourage productivity and process-improvement initiatives.
• Develop a culture of continuous operational improvement.

18. Industrial Safety, EHS & Statutory Compliance

• Establish a strong safety culture across manufacturing operations.
• Ensure appropriate safety measures are implemented before production.
• Monitor machine guarding, interlocks and approved operating procedures.
• Coordinate safe operation of cranes, presses, CNC machines and welding equipment.
• Support appropriate PPE and safe material-handling practices.
• Work with qualified EHS personnel to identify and control workplace hazards.
• Coordinate emergency preparedness and fire safety requirements.
• Ensure incidents and near misses are investigated appropriately.
• Support statutory inspections and factory compliance activities.
• Coordinate corrective actions relating to safety and operational compliance.

19. Supplier, Vendor & Contractor Coordination

• Coordinate with manufacturing equipment suppliers and contractors.
• Review technical requirements for equipment and services.
• Monitor installation and commissioning dependencies.
• Support technical vendor evaluation.
• Coordinate with Procurement regarding production materials and consumables.
• Escalate supplier-related production risks.
• Monitor contractor performance during factory setup.
• Support vendor development for critical equipment and services.
• Ensure technical and operational activities remain within approved budgets and schedules.

20. New Product Development & Manufacturing Readiness

• Coordinate with Engineering and NPD teams on new customer programs.
• Review manufacturing feasibility and capacity requirements.
• Identify tooling, equipment and manpower needs.
• Support prototype, sample and pilot production.
• Ensure production processes and quality requirements are established.
• Coordinate successful transition from trial to regular production.
• Resolve technical bottlenecks affecting new product launches.

21. Factory Expansion & Long-Term Manufacturing Capacity

• Review future production capacity requirements.
• Identify machinery and infrastructure required for growth.
• Support introduction of additional manufacturing lines.
• Develop scalable production systems.
• Improve factory layouts and material flow.
• Build capable departmental management teams.
• Identify opportunities for automation and advanced manufacturing.
• Support long-term operational and manufacturing expansion plans.

Required Experience

• 15–22 years of manufacturing industry experience, including at least 5 years in a senior Plant Head, Plant Manager, Factory Manager, Production Head or equivalent manufacturing leadership position.
• Experience managing manufacturing operations involving multiple departments or production processes.
• Proven experience with greenfield plant setup, factory expansion or major manufacturing commissioning projects.
• Strong understanding of production management, manufacturing processes and factory operations.
• Experience leading Production Managers, Quality, Maintenance, PPC and other manufacturing functions.
• Demonstrated ability to recruit, develop and manage large manufacturing teams.
• Experience with manufacturing budgets, cost control and operational performance management.
• Understanding of machinery installation, commissioning and production ramp-up.
• Knowledge of ERP, production reporting and inventory management.
• Strong problem-solving, decision-making and leadership skills.
• Experience working with manufacturing quality systems, audits and customer requirements.

Preferred Industry Background

Candidates with experience in the following sectors are encouraged to apply:

• Electrical and electromechanical component manufacturing
• Wiring harness and cable assembly manufacturing
• Copper busbar and conductor manufacturing
• Sheet metal fabrication
• Automotive components
• Precision metal fabrication
• Switchgear component manufacturing
• Industrial equipment manufacturing
• Heavy fabrication
• Multi-process industrial manufacturing

Experience across more than one manufacturing process is highly desirable.

The candidate does not need to be a technical specialist in every product category, but must be capable of leading manufacturing experts and coordinating complex operations.

Qualifications

• B.E. / B.Tech in Mechanical, Electrical, Production, Manufacturing or Industrial Engineering.
• MBA / PGDM in Operations or Manufacturing Management preferred, but not mandatory.
• Candidates with a relevant engineering diploma and exceptional proven plant management experience may also be considered.

Practical manufacturing leadership, factory setup experience and operational results are more important than academic qualifications alone.

Ideal Candidate

We are looking for a Plant Head who can independently establish and operate a new multi-factory manufacturing campus.

The ideal candidate should be able to:

• Develop an operational plan for a greenfield manufacturing facility.
• Coordinate factory infrastructure and equipment installation.
• Establish machinery commissioning schedules.
• Recruit and develop departmental Production Managers and technical teams.
• Implement manufacturing process controls and quality systems.
• Develop reliable production planning and reporting systems.
• Establish strong material utilization and inventory controls.
• Monitor factory costs and manufacturing productivity.
• Resolve cross-functional production problems.
• Maintain safe and disciplined manufacturing operations.
• Scale manufacturing capacity as customer demand increases.

The successful candidate must demonstrate hands-on manufacturing leadership, practical engineering judgment, strong execution ability and genuine ownership of factory performance.

We are not looking for someone whose experience is limited to production administration, corporate reporting or supervising only one manufacturing process.

What Success Looks Like

A successful Plant Head will establish a manufacturing operation where:

• Factory commissioning milestones are completed successfully.
• Production machinery and utilities are ready for operation.
• Manufacturing departments have strong leadership and clear accountability.
• Production targets are achieved consistently.
• Quality requirements and customer delivery commitments are met.
• Copper scrap and sheet metal material wastage are controlled.
• Production systems, ERP records and inventory data are accurate.
• Manpower productivity and equipment utilization improve continuously.
• Manufacturing costs remain within approved budgets.
• Workplace safety and compliance requirements are maintained.
• New production lines can be introduced efficiently.
• The factory can scale without compromising manufacturing quality or delivery performance.

This is a senior leadership opportunity to establish and lead a major manufacturing campus for Celestix Industries in Falna, Rajasthan.