Plant Head Surface Treatment

Theia New Consultancy LLP; Tarapur; Sur place; INR 2 500 000 - 4 200 000; Plein temps

Résumé du poste

Theia New Consultancy LLP seeks a Plant Head to own a captive finishing plant (Nickel plating, Ni-Cr, anodizing) from greenfield setup to stable operation. You will ensure process capability, safety compliance, and cost-competitive performance while coordinating cross-functional teams and external vendors.

Responsibilities include commissioning, process stabilization, routine production planning, and driving continuous improvements across coating thickness, corrosion resistance and color

Qualifications

• Expertise in nickel and Ni-Cr plating chemistry and pretreatment.
• Strong control of anodizing processes including dyeing and sealing.
• Experience with ETP and zero-liquid-discharge systems.
• Proficiency in coating-thickness, adhesion, and salt-spray testing.
• Knowledge of lean methods (5S, SPC, FMEA, CAPA) and SAP modules.

Responsabilités

• Lead commissioning and stabilization of captive finishing plant.
• Ensure compliance with MPCB, safety, and environmental standards.
• Own cost per part, utility usage, and process optimization.
• Manage vendor relations, equipment maintenance, and capex tracking.
• Present monthly operating reviews to COO with KPIs and risk management.

Connaissances

Nickel plating chemistry

Ni-Cr plating

Anodizing process control

Coating thickness testing

Salt spray testing

ZLD/ETP technologies

CAPA/TPM/Lean

SAP PP/QM/MM

Outils

SAP PP/QM/MM

Description du poste

Purpose of the Role

To take critical surface treatment processes in-house and run them at consistent quality, statutory compliance and a cost per part at or below the outsourced benchmark.

The role owns the plant end to end: project execution to commissioning, process capability, quality and appearance control (coating thickness, corrosion resistance, colour consistency), environment and safety compliance, and the team. Success means the six EBCO plant units receive finished components on schedule, with fewer chronic finishing issues, and with less dependence on external processors.

The Plant Head builds and runs EBCO's captive Nickel Plating, Anodizing and allied finishing plant from greenfield set-up to a stable, compliant, cost-competitive operation.

Role & responsibilities

A. Set-up and stabilization (greenfield)

• Lead the project to commissioning plant layout and material flow, line and equipment specification, vendor selection, capex tracking against approved budget and schedule.
• Secure all statutory approvals on time: MPCB Consent to Establish and Operate, hazardous waste authorization, Factory license, fire NOC, hazardous chemical storage approvals, and utility connections.
• Design the ETP and zero-liquid-discharge system with the process design, so effluent load is built into line selection, not retrofitted.
• Finalize process recipes, bath chemistry, control plans and work instructions; run trials and PPAP-type approval with plants 11011106 before moving volume in-house.
• Recruit and train the core team (process chemists, line supervisors, lab, ETP, maintenance) and set up SAP master data, routings and costing for captive finishing.
• Plan phased volume transfer from external processors, with a clear exit and fallback plan for each part family.

B. Steady-state operations

• Run daily production to the plant-unit demand plan: line loading, jig and rack utilization, OTIF to internal customers, and WIP control.
• Own bath life and chemistry discipline: analysis frequency, dosing, filtration, drag-out control, and chemical consumption per unit area.
• Hold process capability for coating thickness, adhesion, salt-spray resistance, anodic oxide thickness, sealing quality and colour (Delta E) against drawing and customer norms.
• Drive root-cause closure of rejections and chronic issues with corrective and preventive action, and feed finishing learnings back to design and press shop.
• Own cost per part: power, water, chemicals, anodes, manpower and rework; benchmark every quarter against outsourced rates and report the gap to the COO.
• Plan maintenance (rectifiers, heaters, chillers, pumps, scrubbers, ETP) with a preventive schedule and critical spares.

C. Environment, health and safety

• Ensure zero statutory non-compliance on air, water, hazardous waste and chemical handling; manage consent conditions, returns and audits.
• Build a safety-first culture around acids, cyanide-free chemistry where possible, nickel and chromium exposure, confined space and electrical hazards.
• Drive ISO 14001 and ISO 45001 readiness alongside ISO 9001.

D. People and governance

• Build the unit organisation, succession cover and a technical skill matrix for plating and anodizing.
• Present monthly operating review to the COO: KPI dashboard, capex, compliance status, risks and escalations.
• Manage vendors and chemical suppliers, including technical audits and cost negotiations with Purchase.

Scope of the facility

Nickel plating - Pretreatment (degrease, activation), bright/functional Ni and Ni-Cr, rack and barrel lines, bath chemistry control

Anodizing - Aluminium anodizing, colouring/dyeing and sealing, with Delta E colour control

Effluent and waste - In-house ETP with zero-liquid-discharge intent, hazardous waste handling, sludge disposal, MPCB consents.

Other finishing - PVD, powder coat, passivation (phasing and sequence to be decided with COO)

Support - Testing lab, chemical stores, utilities (DM water, compressed air, power, boiler if needed), maintenance

Preferred candidate profile

Technical competencies

• Nickel and Ni-Cr plating chemistry, pretreatment, rack and barrel line design, adhesion and corrosion performance.
• Anodizing process control: oxide thickness, dye and seal chemistry, colour matching and Delta E management.
• ETP and ZLD technologies, hazardous waste rules, MPCB consent management.
• Test methods and standards: salt spray, coating thickness (XRF, eddy current), sealing tests, adhesion.
• Lean, 5S, SPC, FMEA, CAPA and TPM; working knowledge of SAP PP/QM/MM and process costing.
• Capex planning, vendor negotiation and project scheduling.

Behavioural competencies

• Process-discipline mindset: root-cause logic, data over opinion, no tolerance for shortcuts on chemistry, safety or compliance.
• Builder and operator: comfortable with a bare plot and with running a 24-hour line.
• Strong cross-functional influence with Purchase, Press Shop, Assembly, VDD, Quality and Finance.
• Leads and develops technical teams; calm and decisive under production and regulator pressure.