Plant Head- MOV Manufacturing

Prodocs Solutions; Mumbai; On-site; INR 2,800,000 - 4,000,000; Full time

Job summary

Prodocs Solutions is seeking a seasoned Production and Operations leader for our Mumbai facility. You will drive MOV and TMOV assembly, lead quality management, and coordinate new process introductions with the Directors.

The role requires hands-on experience in electronics manufacturing, ISO/IATF audits, and strong people leadership across shifts; you will champion 5S, SMED and 8D problem-solving while ensuring safe, compliant operations.

Qualifications

• Experience leading large production plants or lines in electronics manufacturing.
• Experience with ISO 9001 / IATF 16949 certifications and customer audits.
• Strong data-driven approach with SPC/PPAP knowledge.

Responsibilities

• Oversee end-to-end MOV production and TMOV assembly, ensuring output, yields and on-time delivery.
• Plan and balance production lines to meet sales orders; manage WIP and changeovers.
• Drive lean programs (5S, SMED, kaizen) and maintain process controls (solder, coating, curing).
• Own QMS documentation, control plans, FMEAs and CAPA actions; lead internal/external audits.
• Coordinate maintenance, preventive/predictive programs for key equipment and utilities.
• Plan capacity expansion with Directors and optimize plant layout and capex proposals.
• Ensure safety, EHS compliance, incident investigation and monthly safety audits.

Skills

Leadership

Quality management

Lean manufacturing

Team management

Education

B.E./B.Tech

Six Sigma

Tools

ERP

Job description

1. Production and operations

• Run the full MOV assembly process starting from imported MOV chips (sourced from China): incoming chip inspection and grading, lead/terminal attachment, soldering, cleaning, epoxy powder coating and curing, marking, 100% electrical testing, taping/forming and packing.
• Run assembly of thermally protected MOVs (TMOV): chip, thermal link and housing assembly and testing.
• Plan daily, weekly and monthly production against sales orders; balance lines across disc sizes (e.g. 7D20D series) and square MOVs (25S/34S/40S).
• Hit output, yield and on-time-delivery targets; cut WIP, scrap and changeover time.
• Control critical parameters: solder profile and joint quality, lead alignment, coating thickness and coverage, cure profile, marking legibility.
• Run shift operations, shift handovers and daily production review meetings.
• Drive lean practices: 5S, visual management, SMED, kaizen and line balancing.

2. Process engineering and new products

• Own process documentation: flow charts, work instructions, control plans and process FMEAs.
• Scale new part numbers and series from samples to mass production; run trials and record process windows.
• Work with chip suppliers on specifications, chip grading and matching chips to finished-­part ratings.
• Support customer-­specific development, PPAP-style approvals and samples for OEM and SPD customers.
• Lead commissioning of new equipment and lines; plan future backward integration (e.g. in-­house chip making) with the Directors.
• Work with the Directors on capacity expansion, layout and capex proposals.

3. Quality Management System (QMS)

• Establish and maintain ISO 9001; prepare the plant for IATF 16949 where automotive customers require it.
• Own document and record control, internal audits, management reviews and the CAPA system.
• Lead customer, certification body and third-­party audits; close findings on time.
• Drive product certification and compliance: IEC 61051, IEC 61643-331, UL 1449 / UL recognition, AEC-Q200 where applicable, and RoHS/REACH declarations.
• Maintain calibration control for all gauges, test benches and surge generators.
• Set up ISO 14001 and ISO 45001 systems as the plant matures.

4. Quality assurance and quality control

• Define inspection at every stage: incoming (MOV chips, leads/terminals, solder, epoxy powder, thermal links), in-­process and final.
• Run incoming chip qualification for every China lot: dimensions, electrode quality, varistor voltage, leakage and sample surge tests; reject or quarantine non-­conforming lots.
• Ensure 100% electrical testing of varistor voltage (V1mA), leakage current and clamping voltage, plus sample surge, energy and life tests.
• Run reliability and qualification testing: 8/20 s surge, 2 ms energy, high-­temperature bias, temperature cycling, damp heat, solderability.
• Apply SPC and capability studies (Cp/Cpk) to critical parameters; trigger action on out-­of-­control trends.
• Handle customer complaints and returns with 8D and root-­cause analysis; issue CoCs and test reports.
• Run supplier quality for overseas chip vendors: vendor approval, lot data review, supplier corrective actions and periodic audits.

5. Maintenance and equipment

• Own preventive and predictive maintenance for lead-­forming and soldering machines, coating and curing ovens, marking machines, auto-­testers and taping machines.
• Track breakdowns, MTBF and MTTR; keep critical spares in stock.
• Coordinate utilities: power, compressed air and exhaust/ventilation.

6. Materials, stores and supply chain

• Plan chip and raw material requirements with purchase; maintain safety stock against import lead times.
• Coordinate with purchase on import shipments, customs clearance timelines and inward inspection of chip consignments.
• Control stores, FIFO, lot traceability (chip lot to finished lot) and shelf-­life items (solder, epoxy powder).
• Run monthly inventory reconciliation and keep stock accuracy above target.

7. Environment, health and safety (EHS)

• Ensure safe handling of soldering fumes, epoxy powder, curing ovens, high-­voltage and surge test areas and chemicals.
• Enforce PPE, dust and fume control, fire safety, electrical safety and emergency procedures.
• Keep Factories Act, MPCB and fire NOC compliance current; maintain statutory registers.
• Investigate incidents and near misses; run monthly safety audits.

8. Training and skill development

• Build a training plan for every role: induction, on‑the‑job training and refreshers.
• Maintain a skill matrix for each operator and line; certify operators before they run critical stations.
• Train teams in QMS, SPC, 5S, 8D, ESD awareness and safety.
• Develop supervisors and engineers into future section heads; plan succession for key roles

9. Company organization and people

• Design the plant organization: departments, reporting lines, roles, shift structure and manpower plan.
• Write and maintain job descriptions, KRAs and approval authorities for each plant role.
• Recruit plant staff with HR; run appraisals, attendance, discipline and grievance handling.
• Manage contract labor and statutory compliance (PF, ESIC, contract labor rules).
• Build a culture of ownership, quality and safety; run regular communication meetings with all staff.
• Coordinate with the group's Bhiwandi facility and head office on shared systems, transfers and best practices.

10. Cost, budget and reporting

• Prepare and run the plant budget: manpower, power, consumables, maintenance and capex.
• Track cost per unit by series; reduce material, energy and conversion costs.
• Report a monthly MIS to the Directors: output, yield, quality, delivery, cost, safety and people metrics.

Education:

• B.E./B.Tech (mandatory).
• Six Sigma certification preferred.

Experience:

• 10-12 years in electronics manufacturing or passive components.
• Experience leading a plant, factory or large production unit, with budget responsibility.
• Hands-­on experience of component assembly: soldering, coating, curing, automated testing and packing.
• Experience managing imported materials and overseas suppliers is an advantage.
• Track record of leading ISO 9001 (IATF 16949 a plus) certification and customer audits.
• Experience setting up a new plant or line from start-­up is a strong advantage.

Technical knowledge:

• MOV construction, ratings and test methods: V1mA, leakage, clamping voltage, 8/20 s surge, energy rating.
• Relevant standards: IEC 61051, IEC 61643-331, UL 1449; familiarity with AEC-Q200 and RoHS/REACH.
• Quality tools: SPC, FMEA, control plans, MSA, 8D, 7 QC tools, PPAP basics.
• Lean manufacturing, TPM and 5S.
• ERP-­based production planning and inventory control.

Leadership and personal skills:

• Builds and leads teams of engineers, supervisors and operators across shifts.
• Strong decision-­making under delivery and quality pressure.
• Clear communicator in English, Hindi and Marathi with staff, customers and auditors.
• Data-­driven; reports with numbers, not opinions.
• High integrity on quality and safety; willing to stop a line for a quality issue.

Other Details:

• Working days: 6 days a week, general shift, with availability for shift-­critical issues.
• Work Location: Andheri East,Mumbai

CTC: commensurate with experience; performance bonus linked to plant KPIs.