Head- Film Production

Ester Industries Limited; Hyderabad; On-site; INR 2,500,000 - 3,800,000; Full time

Job summary

Ester Industries Limited in Hyderabad is seeking a Head Film Production to lead end-to-end manufacturing on the Film Production Line, metallizers and slitting operations, ensuring safe, efficient and cost-effective production aligned with business objectives.

You will drive OEE, oversee TPM and Lean initiatives, lead continuous improvement, and collaborate with Maintenance, Quality, Planning, SCM and Technical Services to achieve world-class manufacturing performance while building

Responsibilities

• Lead complete production operations of the assigned Film Production Line across all shifts.
• Ensure achievement of daily, weekly and monthly production targets as per Annual Operating Plan.
• Ensure optimum utilization of machines, manpower, utilities and production resources.
• Monitor Overall Equipment Effectiveness (OEE) and drive improvement initiatives.
• Drive manufacturing excellence through TPM, Lean Manufacturing, Kaizen and Continuous Improvement initiatives.
• Improve productivity, throughput and machine efficiencies.
• Maintain First Pass Yield (Net to Extrusion) comparable to best in industry.
• Improve process capability and manufacturing stability.
• Lead root cause analysis and implementation of corrective and preventive actions.
• Ensure strict adherence to approved process parameters, SOPs, Work Instructions and Quality Standards.
• Lead commercialization of new products and successful execution of NPD trials.
• Standardize process parameters after successful validation.
• Resolve all process-related abnormalities through systematic troubleshooting.
• Ensure production of customer-compliant products with minimum rejection.
• Drive First Time Right (FTR) manufacturing.
• Ensure zero customer complaint.
• Review quality trends and implement preventive actions.
• Ensure timely CAPA closure for customer complaints and internal quality issues.
• Monitor manufacturing cost and identify improvement opportunities.
• Optimize consumption of raw materials, chemicals, utilities and consumables.
• Reduce inventory carrying cost through effective production planning.
• Drive cost reduction projects without compromising quality and safety.
• Support budgeting and cost control initiatives.
• Ensure maximum machine availability through effective preventive maintenance planning.
• Coordinate shutdown planning, die changes, chain maintenance and critical equipment overhauls.
• Reduce breakdown frequency and Mean Time to Repair (MTTR).
• Improve equipment reliability through proactive maintenance practices.
• Build and sustain a strong safety culture across production operations.
• Ensure compliance with all statutory, environmental and organizational safety requirements.
• Achieve Zero Lost Time Injury (LTI) and Zero Reportable Safety Incidents.
• Ensure implementation of Risk Assessment, PPE compliance and Safe Work Practices.
• Promote sustainability initiatives related to waste reduction, energy conservation and environmental compliance.
• Lead, coach and mentor Sr. Team Members and Team Members.
• Develop technical capability and leadership pipeline within the department.
• Ensure competency development through structured training plans.
• Conduct performance reviews and provide regular feedback.
• Build a culture of accountability, ownership and continuous learning.
• Coordinate with Planning for production scheduling.
• Work closely with QA to improve product quality.
• Coordinate with Maintenance to maximize equipment uptime.
• Liaise with SCM, Purchase and Stores for timely material availability.
• Support Business Development during product commercialization.
• Drive digitalization and automation initiatives in manufacturing.
• Lead departmental improvement projects.
• Benchmark production performance against industry best practices.
• Improve customer satisfaction through consistent delivery performance.
• Support strategic manufacturing initiatives assigned by Plant Leadership.
• Review daily production performance and initiate corrective actions.
• Present departmental KPIs during Plant Review Meetings.
• Ensure accuracy of production reports and SAP transactions.
• Maintain statutory and ISO documentation.
• Ensure audit readiness at all times.
• Additional Responsibility
• Support Plant Head in achieving annual business objectives.
• Lead implementation of IMS, ISO, FSMS, TPM and Operational Excellence initiatives.
• Participate in CAPEX planning and commissioning of new equipment.
• Ensure succession planning and manpower development.
• Drive employee engagement activities within production.
• Support customer audits and certification audits.
• Perform any additional responsibilities assigned by Management.

Skills

Film Manufacturing Process and Metall{

Education

B.Tech/ Diploma in Engineering

Job description

Job purpose

• The Head Film Production is responsible for leading end-to-end manufacturing operations of the assigned Film Production Line production, metallizers and slitting operations by ensuring safe, efficient, and cost-effective production while consistently achieving business objectives related to productivity, quality, delivery, safety, cost, and people development.

• The role provides operational leadership to the production team, ensures optimum utilization of manpower, machinery, materials and utilities, drives continuous improvement initiatives, and works closely with Maintenance, Quality, Planning, SCM and Technical Services to achieve organizational goals.

• The incumbent is accountable for maximizing Overall Equipment Effectiveness (OEE), reducing manufacturing losses, ensuring regulatory compliance, building high-performing teams, and delivering world-class manufacturing performance.

Key duties and responsibilities

• Lead complete production operations of the assigned Film Production Line across all shifts.
• Ensure achievement of daily, weekly and monthly production targets as per Annual Operating Plan.
• Ensure optimum utilization of machines, manpower, utilities and production resources.
• Monitor Overall Equipment Effectiveness (OEE) and drive improvement initiatives.
• Drive manufacturing excellence through TPM, Lean Manufacturing, Kaizen and Continuous Improvement initiatives.
• Improve productivity, throughput and machine efficiencies.
• Maintain First Pass Yield (Net to Extrusion) comparable to best in industry.
• Improve process capability and manufacturing stability.
• Lead root cause analysis and implementation of corrective and preventive actions.
• Ensure strict adherence to approved process parameters, SOPs, Work Instructions and Quality Standards.
• Lead commercialization of new products and successful execution of NPD trials.
• Standardize process parameters after successful validation.
• Resolve all process-related abnormalities through systematic troubleshooting.
• Ensure production of customer-compliant products with minimum rejection.
• Drive First Time Right (FTR) manufacturing.
• Ensure zero customer complaint.
• Review quality trends and implement preventive actions.
• Ensure timely CAPA closure for customer complaints and internal quality issues.
• Monitor manufacturing cost and identify improvement opportunities.
• Optimize consumption of raw materials, chemicals, utilities and consumables.
• Reduce inventory carrying cost through effective production planning.
• Drive cost reduction projects without compromising quality and safety.
• Support budgeting and cost control initiatives.
• Ensure maximum machine availability through effective preventive maintenance planning.
• Coordinate shutdown planning, die changes, chain maintenance and critical equipment overhauls.
• Reduce breakdown frequency and Mean Time to Repair (MTTR).
• Improve equipment reliability through proactive maintenance practices.
• Build and sustain a strong safety culture across production operations.
• Ensure compliance with all statutory, environmental and organizational safety requirements.
• Achieve Zero Lost Time Injury (LTI) and Zero Reportable Safety Incidents.
• Ensure implementation of Risk Assessment, PPE compliance and Safe Work Practices.
• Promote sustainability initiatives related to waste reduction, energy conservation and environmental compliance.
• Lead, coach and mentor Sr. Team Members and Team Members.
• Develop technical capability and leadership pipeline within the department.
• Ensure competency development through structured training plans.
• Conduct performance reviews and provide regular feedback.
• Build a culture of accountability, ownership and continuous learning.
• Coordinate with Planning for production scheduling.
• Work closely with QA to improve product quality.
• Coordinate with Maintenance to maximize equipment uptime.
• Liaise with SCM, Purchase and Stores for timely material availability.
• Support Business Development during product commercialization.
• Drive digitalization and automation initiatives in manufacturing.
• Lead departmental improvement projects.
• Benchmark production performance against industry best practices.
• Improve customer satisfaction through consistent delivery performance.
• Support strategic manufacturing initiatives assigned by Plant Leadership.
• Review daily production performance and initiate corrective actions.
• Present departmental KPIs during Plant Review Meetings.
• Ensure accuracy of production reports and SAP transactions.
• Maintain statutory and ISO documentation.
• Ensure audit readiness at all times.
• Additional Responsibility
• Support Plant Head in achieving annual business objectives.
• Lead implementation of IMS, ISO, FSMS, TPM and Operational Excellence initiatives.
• Participate in CAPEX planning and commissioning of new equipment.
• Ensure succession planning and manpower development.
• Drive employee engagement activities within production.
• Support customer audits and certification audits.
• Perform any additional responsibilities assigned by Management.

Skills and Knowledge

• Film Manufacturing Process and Metallisation.
• Production Planning & Control
• Lean Manufacturing
• TPM
• OEE Improvement
• Root Cause Analysis
• SAP
• MS Office
• ISO / IMS / FSMS
• Cost Optimization

Qualification

B.Tech/ Diploma in Engineering.