Senior Manager/Deputy General Manager Production

HarbisonWalker International; Katni; On-site; INR 2,500,000 - 4,500,000; Full time

Job summary

HarbisonWalker International in India seeks a senior production/EHS specialist with 10-15 years in refractory production. You will oversee SAP-PP operations, BOM and routing management, and ensure compliance with IMS, ISO 50001, and factory inspections.

You will drive 5S, Kaizen, and OPEX initiatives, mentor teams on safe behaviours, coordinate with QA for testing, and manage cost control and dashboards on the shop floor.

Qualifications

• Education: B.Tech in Ceramic Engineering, Chemical Engineering or Mechanical Engineering.
• 10–15 years of experience in refractory production or manufacturing.
• Experience in SAP MM/PP, process control and cost analysis preferred.

Responsibilities

• SAP – PP module operation: create production orders, maintain BOM & routing, monitor WIP/FG costs.
• Prepare daily/ monthly production reports and headcount billing reconciliation.
• Ensure IMS/ISO 50001 compliance and complete EHS audits.
• Lead 5S, Kaizen initiatives and OPEX projects on the shop floor.
• Develop and mentor teams on safe behaviours and regulatory requirements.
• Coordinate with QA for testing and with stores for material availability.

Skills

SAP

Microsoft Office

Kaizen

Education

B.Tech in Ceramic Engineering / Chemical Engineering / Mechanical Engineering

Tools

SAP PP module

Power Apps

MS Office

Job description

Responsibilities:

EHS:

• Must ensure that all his team workers use all mandatory (Safety Helmet, Safety Goggle, Safety Shoes
  & High Visibility Jacket) and relevant work related PPE's before starting any activity
• Ensure daily Safety Toolbox Meeting at the beginning of shift in all lines/equipments
• Must ensure effective implementation & sustenance of all work permits, Company's cardinal rules &
  Take 5 in their respective sections & area .
• Must ensure the active participation in reporting, investigation, rectification / compliance of both
  corrective & preventive measures of all incidents, accidents & SOFI items.
• Must actively participate in all Company's Safety program / drives (S7, SCIT, EHS Peer Review
  Audit, 5S etc.) and drive its effective implementation and sustenance in their respective work areas
  & team .
• Must conduct monthly 5S & S7 audit.
• Must coach all his team members on Safe Behaviours & initiate disciplinary action on any safety rule
  violation as per company policy.

JOB RELATED:

• Ensuring the timely production of Monolithics & Ready shape (Lance & PCPF shapes) Products as
  per dispatch / S&OP plan.
• Production Planning and provide Raw Material & other consumables requirements to the PPC
  Team.
• Mass balance of raw materials and finished goods.
• Ensuring smooth operation and process control of the equipment.
• Coordination with stores for other consumable material ( i.e.Packing, chemical, tools, safety item etc.)
• Conduction Job-specific trainings including SOP, HIRA etc.
• Meeting statutory and regulatory norms like factory inspection, stock taking audit, ISO audits etc.
• Meeting IMS standards in process and maintaining documentation.
• Actively participate in continuous improvement programs and Opex initiatives.
• Involvement in Day to Day activities of Crushing & Grinding circuit.
• Meeting all KPIs related to production.
• Interaction with internal & external stakeholders.
• Preparation and verifying all contractor bills related to production.
• Conducting vendor and customer visits as and when required.
• Contributing in relevant Capex projects meeting all deliverables.
• Contributing in Developmental jobs.

Detailed Job Description:

1. SAP –PP module operation.

• Making production order of all products.
• Creating and maintaining BOM & Routing of products in SAP.
• Running and maintaining standard cost of all WIP & FG products.
• Stock monitoring of Monolithics Line Finished Goods and raw materials.
• Cost control (raw material, labour, power, depreciation, packing cost etc) and cost analysis of products.

2. Reports:

• Daily production data reporting of all production lines and variance analysis.
• Maintaining monthly reports pertaining to all production lines, weighment report etc
• Headcount reporting
• Monthly billing reconciliation of contractors.
• Maintaining all data of Power app.
• Preparing monthly and quarterly plant performance review reports.
  

3. Quality Related:

• Follow QC instruction to ensure zero non conformity and customer claims.
• Visual checking of Product packing detail and analysis of batching report.
• Coordination with Quality team for smooth online / offline testing of Product.
• Random checking of green and fired blocks along with moulds of RDS items.
  

4. Projects:

• New capex or Opex project execution as and when required.
• Execution of production trial and making report.
• Implementation of dashboard in shop floor.
  

5. Developmental jobs & OPEX

• Implementation of OPEX action plans
• Sustenance of 5S
• KAIZEN initiatives and reporting.
• Quality circle activity for specific projects.
• Mentoring and executing siz sigma projects.
  

6. Statutory compliance jobs

• Compliance/ Documentation of IMS and ISO 50001 system
• EHS/ 5S audit compliance
  

7. EHS activities and compliance of audit findings

• Monthly audits (Internal & External), conducting HIRA and other risk assessments.
• Ensuring all EHS guidelines and protocols are followed.

Profile/Competencies:

• Education - B. Tech- Ceramic Engineering/ Chemical Engineering/ Mechanical Engineering
• Background - Preferably worked before in Refractory Production unit
  Level of experience – 10-15 years minimum
  

Preferred certification:

• Six sigma green or black Belt, IMS and energy auditing.
  

Work experience:

• Earlier work experience in the Refractory Industry in production unit.
  Preference will be given to the candidates having experiences in manufacturing of Refractory products.
  Experience in operation & process controls of Calcination, drying, crushing and grinding operation and
  material handling equipment are desirable. Sound knowledge of SAP and Microsoft office is required.