Plant Head Transformer Manufacturing

Western Electrical Unit No 2; Bhopal; On-site; INR 2,500,000 - 4,500,000; Full time

Job summary

Western Electrical Unit No 2 is seeking a Plant Head to lead end-to-end transformer manufacturing, overseeing production planning, resource allocation, and cross‑functional coordination to meet committed delivery schedules and quality targets.

You will guide the Quality, Testing and After-Sales teams, drive root cause analysis, implement CAPA, ensure IS/IEC compliance, and spearhead continuous improvement and safety initiatives while maintaining discipline across all departments.

Job description

Role & responsibilities

Key Responsibilities

1. Production Planning & Execution

• Prepare daily, weekly and monthly production plans based on committed delivery schedules.
• Plan and coordinate activities across winding, core, assembly, tanking, ovening, oil filtration, testing and dispatch.
• Monitor production against targets and identify bottlenecks affecting delivery.
• Ensure availability and proper allocation of manpower, machines, materials and other resources.
• Coordinate with Purchase, Stores, Design and Quality teams to prevent production delays.
• Improve productivity and reduce manufacturing cycle time and rework.

2. Quality & Process Control

• Lead and guide the Quality team for incoming, in-process and final inspection.
• Ensure adherence to approved drawings, GTPs, manufacturing procedures and applicable IS/IEC/customer specifications.
• Establish appropriate stage-wise quality checks and hold points.
• Ensure proper documentation and traceability of critical manufacturing activities.
• Drive reduction in rejection, rework and recurring quality issues.

3. Root Cause Analysis & Troubleshooting

A major requirement of this position is the ability to technically investigate manufacturing and testing failures.

The Plant Head should be able to:

• Investigate in-process failures and abnormalities.
• Perform structured Root Cause Analysis (RCA).
• Identify whether the problem originates from design, material, workmanship, process or testing.
• Define and implement Corrective and Preventive Actions (CAPA).

Guide the team in troubleshooting issues such as:

• Low IR/Mgger values
• Ratio/tap-position abnormalities
• High resistance or unbalance
• Excessive losses
• Impedance deviations
• HV/LV withstand failures
• Induced/DVDF test failures
• Oil leakage
• Temperature-rise related issues
• Other routine and type-test abnormalities

• Maintain records of major failures and ensure learning is incorporated into future manufacturing.

4. Testing & Customer Inspections

• Ensure transformers are completely ready before customer/third-party inspection.
• Review internal test results before offering transformers for inspection.
• Coordinate and handle inspections by customers, utilities and third-party agencies.
• Technically represent the company during inspections and resolve observations raised by inspectors.
• Ensure testing is carried out according to applicable IS/IEC standards and approved specifications.
• Ensure inspection observations and NCRs are closed within defined timelines.

5. Team Leadership

• Lead Production, Quality and Testing teams and establish clear accountability.
• Conduct regular production and quality review meetings.
• Guide engineers and supervisors in solving day-to-day technical and operational problems.
• Develop technical capability of junior engineers through practical training and mentoring.
• Maintain discipline, safety and coordination across departments.
• Evaluate manpower requirements and support recruitment and development of the plant team.

6. After-Sales & Site Support

• Technically guide the after-sales/service team for transformer-related complaints.
• Analyse customer complaints and determine probable root causes before deputing teams to site.
• Guide site teams regarding required checks, instruments and corrective actions.
• Review site failure reports and determine whether issues relate to manufacturing, installation, protection, loading or site conditions.
• Ensure customer complaints are closed quickly while protecting the companys technical and commercial interests.
• Feed learnings from site failures back into Production, Design and Quality.

7. Dispatch & Delivery Responsibility

• Ensure transformers are technically and commercially ready for dispatch as per committed schedules.
• Review pending jobs and proactively elevate risks to delivery.
• Coordinate inspection clearance, testing documentation, accessories, packing and dispatch readiness.
• Ensure transformers are dispatched without pending technical or quality issues.

8. Continuous Improvement

• Identify bottlenecks and opportunities for improvement across manufacturing processes.
• Implement systems for reducing rejection, rework, testing failures and production delays.
• Develop SOPs, checklists and process controls for critical activities.
• Track recurring problems and ensure permanent corrective action rather than temporary solutions.
• Promote 5S, workplace safety and preventive maintenance practices.

Key Performance Indicators (KPIs)

Performance of the Plant Head will primarily be measured on:

• On-time production and dispatch
• Production plan vs. actual achievement
• First-pass testing success rate
• In-process rejection and rework
• Customer inspection clearance / first-time acceptance
• Reduction in recurring quality failures
• Customer/site complaint closure time
• Manufacturing cycle time
• Productivity and manpower utilisation
• Compliance with quality and safety systems