Manufacturing Operations - AVP|SVP|VP

AVP / VP / SVP — Manufacturing Operations (Plant Head & Statutory Factory Manager | MAH Site with ZLD | Location: Dahej, GIDC, Gujarat) Reports to: MD & CEO and Chairman (strong operating interfaces with COO, CFO, CPO, Heads of Sustainability/EHS, Projects, QA/QC, Supply Chain, Sales) Span: ~250 employees + contract workforce | 24×7, multi-block operations Education: B.E./M.E. (Chemical) or M.Sc. (Organic) | Advanced safety credentials preferred (ADIS/NEBOSH/PSM) Experience: ~25+ years in specialty/organic chemicals with 10+ years running MAH classified plants end-to-end; proven ZLD and statutory credibility 1) Mission (Why this role exists) Own the Dahej plant P&L while protecting People, Environment, and License to Operate. Deliver the plan right-first-time, every time. Build a system that runs on standards, not heroics. 2) Operating Context (Dahej & Gujarat realities) • MAH-classified site; strong Process Safety Management (HAZID/HAZOP, MoC, PSSR, LOPA, alarms/SIS). • ZLD commitment: Stable RO → Multiple Effect Evaporator (MEE) → ATFD with auditable OCEMS/flow/energy data. • Regulatory ecosystem: DISH (Gujarat), GPCB (Air/Water/CCA, OCEMS), PESO, Boiler Inspectorate, Electrical Inspectorate, local Fire & Emergency, GIDC (utilities & ROW), GMB/port for HAZMAT logistics. • Legal frameworks (India & Gujarat): Factories Act & Gujarat Factory Rules; EPA 1986; Water Act 1974; Air Act 1981; Hazardous & Other Wastes Rules 2016; MSIHC Rules 1989; Chemical Accidents (EPPR) Rules 1996; Explosives & Gas Cylinder Rules; IS standards for storage/handling; IMDG/ADR as applicable to exports. • Digital backbone: ERP (TCS iON or equivalent), historian/MES, OCEMS, DCS/PLC/SIS; audit-grade data integrity. 3) What Success Looks Like (12-Month Outcomes) Safety & People • TRIR = 0.00; 100% High-Risk PTW audits “error-free”; 2 emergency drills/quarter. • Leadership gemba ≥24 hrs/month with actioned safety observations ≥20/month. Compliance & Reputation • All licenses/consents current; zero show-cause/closure notices; OCEMS uptime ≥95%; statutory registers perfect. Output, Reliability & Quality • AOP adherence (volume & mix) ≥98%; unplanned downtime −30% YoY; OEE +7 p.p. YoY. • OTIF ≥98%; major audit findings 0; Cost of Quality −15–20% YoY. Environment & ZLD • 100% consent-adherent days; RO recovery ≥75–80%; MEE steam economy +5 8% YoY; MEE uptime ≥92%; specific water/steam/power intensities trending down monthly. Cost & Margin • Cost/ton −5–7% YoY; Gross margin +150–250 bps via yield, solvent recovery, energy optimization, chronic loss elimination. Capability & Succession • Two ready successors (Production/EHS) with validated skills; 100% critical roles certified. 4) Core Responsibilities (Expanded) A. Process Safety & Statutory • Act as statutory Factory Manager; assert stop-work on any risk. • Own PSM elements: HAZOP/LOPA cadence; MoC discipline; PSSR; alarm rationalization & flood control; SIS proof-testing; contractor safety. • Ensure PESO, Boiler, Electrical, Fire NOC, Factory License, GPCB CCA/consents, OCEMS calibration/compliance—always audit-ready. • Emergency preparedness: on-site plan, off-site linkages (district administration/Fire/GIDC), mutual aid, trauma/OHC readiness. B. Production & Planning • Translate AOP to weekly/daily finite schedules; protect critical path and material availability. • Stabilize cycle times; minimize changeover losses; manage campaign strategies for product mix. C. Environment, ZLD & OCEMS • Keep RO–MEE–ATFD stable; manage shocks (COD/TOC/TDS spikes); maintain manifests/TSDF/CETP compliances. • Sustain OCEMS uptime and data integrity (QA/QC of instruments, drift checks, third-party calibration). D. Reliability & Utilities • Shift from breakdown to RCM/CBM/PM; improve MTBF/MTTR; maintain critical spares. • Utilities reliability (power/steam/water/air/inert gases); post-shutdown performance verification. E. Quality & Customer • Right-first-time COAs; traceability/batch genealogy; holds & deviations with fast CAPA. • Zero surprises in customer/ISO/Reg body audits; DG/IMDG compliance where applicable. F. Supply Chain, Stores & Dispatch • S&OP discipline with Sales/SCM; RM/PM assurance with QC release timing. • Inventory accuracy ≥99%; FIFO/FEFO; complete dispatch documentation; rail/road/port HAZMAT readiness. G. Projects & Capex • Stage-gate governance; constructability with safety; commissioning tied to capability & SOPs; real benefits realized in P&L. H. People, Culture & IR • Safe, disciplined, respectful shop-floor; clear role charters; skill matrices; PoSH compliance. • Contractor governance: induction, PTW readiness, PPE, wages/records per law (principal employer lens). I. Digital, Data & ERP • “If it’s not in the system, it didn’t happen.” RFT transactions; robust master data; audit trails; dashboards (OEE, energy, ZLD, OTIF). J. Stakeholder & External Affairs • Credible relationships with DISH, GPCB, Fire, GIDC, PESO, local administration, CETP/TSDF operators, GMB/port stakeholders, community. 5) KPIs & Definitions (governed monthly; weekly where noted) • TRIR = (Recordables × 200,000) ÷ Hours worked → Target 0.00. • OTIF = On-Time, In-Full ÷ Total dispatches → ≥98%. • OEE = Availability × Performance × Quality → +7 p.p. YoY uplift. • Unplanned downtime: hours/month → −30% YoY. • COQ (Prevention + Appraisal + Failure) → −15–20% YoY. • OCEMS uptime (valid data availability) → ≥95%. • RO recovery (Permeate ÷ Feed) → ≥75–80%. • MEE steam economy (kg water evaporated ÷ kg steam) → +5–8% YoY. • Inventory accuracy (cycle counts & annual stock-take) → ≥99%. 6) Governance Cadence (simple, repeatable rhythm) • Daily: Safety & plan-vs-actual, holds, alarms, permits; remove bottlenecks. • Weekly: Reliability top-loss, ZLD/OCEMS & energy review, CAPA closures, staffing/contractor governance. • Monthly: S&OP; statutory dashboard; inventory & dispatch review; financial bridge. • Quarterly: ESG/risk review; joint emergency drill; board-ready update. • Annually: AOP build; surveillance/recert audits; capability plan. 7) Decision Rights & Delegation of Authority (DoA) • Non-negotiable: Stop production for safety/compliance. • Approve production schedules, shutdown/TA plans, and critical hires for plant. • Sign statutory submissions as Factory Manager per authority matrix. • Co-own P&L bridges and savings realization with Finance. • Capex approvals per DoA; project gate reviews mandatory. 8) Collaboration Map • Internal: Sales (S&OP), SCM (RM/PM, logistics), QA/QC (release/holds), Projects (capex), EHS (PSM/ZLD), Engineering (reliability), Finance (bridges), HR/IT (capability/digital). • External: DISH, GPCB, PESO, Boiler/Electrical, Fire, GIDC, GMB/port, CETP/TSDF, certification bodies, emergency services. 9) Candidate Profile (who thrives here) Must-have • ~25 years in chemicals with MAH exposure; 10+ as Plant Head/No.2. • Strong in hydrogenation/oxidation/reduction and large-scale distillation; proven runaway-risk prevention. • ZLD (RO–MEE–ATFD) governance; OCEMS/consent credibility; closed tough audits. • Data-first mindset; DCS/PLC/SIS familiarity; alarm rationalization. • Fluent English/Hindi; Gujarati preferred for site effectiveness; 24×7 availability for emergencies. Good-to-have • TPM/Lean/Six Sigma; APC/MPC; digital MoC; alarm management center; renewables/energy transition; port/IMDG experience. Leadership DNA • Safety absolutist; decisive and systems-thinking; talent multiplier; stakeholder savvy; low-ego/high-ownership. 10) Qualifications & Certifications • B.E./M.E. (Chemical) or M.Sc. (Organic); AFIH/NEBOSH/PSM preferred. • Boiler/Electrical exposure; ISO 9001/14001/45001; TfS/EcoVadis familiarity. 11) 30-60-90 Day Onboarding Plan (outcomes, not activities) First 30 Days (Stabilize & See) • Statutory gap assessment: licenses, consents, registers, OCEMS health check; Red/Amber/Green with owners & due dates. • “Top-10 losses” baseline for safety, downtime, energy, ZLD; freeze definitions & data sources. • Validate people structure, shift rosters, contractor governance; confirm critical skills & training needs. • Freeze governance cadence and KPI pack; start daily tier huddles. Days 31–60 (Fix & Prove) • Close the top 5 safety risks (engineering + procedural fixes) with evidence. • Stabilize RO–MEE–ATFD parameters (SOPs/limits); implement OCEMS calibration/QA plan. • Launch reliability boosters (RCM/CBM pilots on 3 critical assets); secure spares. • Hit first OTIF ≥96% month; reduce unplanned downtime by ≥10% vs. baseline. Days 61–90 (Scale & Lock-in) • Extend RCM/CBM; codify leader standard work; publish “golden parameters” and visual controls. • Show COQ −5% vs. baseline; OEE +2 p.p. vs. baseline; energy & water intensities trending down 2 consecutive months. • Present FY P&L bridge with validated savings & roadmap. 12) Interview Rubric & Case Prompts (for structured, bias-aware selection) Rubric (score each 1–5) 1. Process safety depth (HAZOP/LOPA/MoC/PSSR, alarm/SIS). 2. ZLD/OCEMS credibility and evidence of stabilization. 3. Reliability engineering (RCM/CBM/MTBF/critical spares). 4. Plant P&L and cost/ton levers (yield/energy/solvent recovery). 5. Leadership & culture (contractor safety, IR maturity, accountability systems). 6. Data integrity & digital fluency (ERP/MES/historian). 7. Stakeholder management (DISH/GPCB/PESO/Fire/GIDC/GMB, customers). Case Prompts • Runaway prevention: Given a hydrogenation runaway near-miss with three alarm f loods, design a 4-week MoC/PSSR/LOPA response. • ZLD upset: RO recovery falls to 60%, MEE salt carry-over rises—diagnose, stabilize, and prove control. • OTIF failure: 94% OTIF month due to changeovers—fix plan, maintenance windows, and dispatch governance. 13) Compensation & Enablers • Market-leading fixed; performance-linked variable; profit-share eligibility as per company policy. • Defined DoA; executive onboarding; relocation support (as justified). • Tools: ERP, historian/MES, real-time dashboards; training budget tied to capability plan. 14) Equal Opportunity & Conduct We are an equal-opportunity employer committed to a safe, respectful, and inclusive workplace. Offers are contingent on background checks and adherence to our Code of Conduct and PoSH policy. 15) Non-Negotiables (be explicit) • Safety before output—every time. • Data integrity: no backdating, no “offline fixes”; OCEMS honesty. • Statutory never slips; renewals are calendarized and evidentiary. • Leadership presence on the floor, not just in review rooms. 16) How to Apply Email CV plus two one-pagers: 1. A serious incident you prevented (baseline → interventions → results). 2. A ZLD stabilization you led (data before/after, controls sustained). Subject: Application — Plant Head (MAH & ZLD | Dahej, Gujarat) Company Email: HR@harmonyorganics.in