The Plant Head will be responsible for the overall management and operation of the FIBC (Flexible Intermediate Bulk Container) manufacturing unit. This includes overseeing tape plant operations, loom efficiency and output, and ensuring high-quality FIBC finishing and bag-making processes. The role demands expertise in production planning, cost control, BOM (Bill of Materials) calculation, workforce management, reducing wastage, and continuous process improvement to meet production targets and ensure operational excellence.

Overall Responsibilities: 

Managing tape plant operations, loom efficiency, FIBC finishing, production planning, quality control, cost management, and workforce training.

Key Responsibilities:

Production Management

·        Oversee the end-to-end operations of the Tape Plant, ensuring smooth production of tapes with desired quality and deniers.

·        Monitor Loom Operations to maximize efficiency, optimize loom uptime, and meet fabric output targets.

·        Ensure high-quality FIBC Finishing and Bag-Making Processes, including stitching, printing, and quality control.

·        Plan, implement, and monitor daily, weekly, and monthly production schedules to meet delivery deadlines.

·        Carry out PPC Activities on a weekly basis.

·        Carry out Preventive Maintenance.

Efficiency and Output Optimization

·        Analyze and improve loom efficiency to achieve maximum fabric output with minimal downtime.

·        Optimize raw material usage to minimize wastage and control production costs.

·        Ensure that BOM calculations are accurate and cost-effective, taking into account material, labour, and process requirements.

·        Standardize Deniers and Fabric GSM to make processes more efficient.

Wastage Reduction

·        Identify areas of material wastage across all production processes and implement measures to minimize it.

·        Develop strategies for reusing or recycling production waste wherever feasible.

·        Monitor wastage metrics regularly and set improvement targets for the team.          

Quality Control

·        Establish and monitor quality standards for raw materials, semi-finished goods, and finished FIBC products.

·        Conduct regular quality audits to ensure compliance with customer specifications and international standards.

Workforce Management

·        Train and guide new and existing workers, especially stitchers, to ensure a flexible and skilled workforce capable of handling rotation schedules.

·        Develop skill enhancement programs for workers to improve productivity and maintain quality standards.

·        Monitor worker performance and ensure adherence to health and safety protocols.

Cost Management

·        Prepare and manage budgets for the plant, including cost analysis and resource allocation.

·        Ensure efficient utilization of resources to maintain profitability while meeting production targets.

Process Improvement

·        Drive continuous improvement initiatives to enhance productivity, reduce waste, and improve overall operational efficiency.

·        Stay updated on the latest technologies and practices in FIBC manufacturing and implement relevant upgrades.             

Leadership and Team Management

·        Lead and mentor the plant team, fostering a culture of teamwork, accountability, and excellence.

·        Handle conflict resolution and ensure smooth coordination between departments such as production, maintenance, and quality.                   

 

Key Skills and Qualifications:

·        Bachelor’s degree in Engineering, Production Management, or a related field (preferred).

·        Minimum 10-15 years of experience in FIBC manufacturing, including hands-on experience in Tape Plant Operations, Loom Management, and FIBC Bag Finishing.

·        Strong knowledge of BOM (Bill of Materials) preparation and cost optimization.

·        Proven leadership abilities, with experience in managing and training diverse teams.

·        Excellent problem-solving and decision-making skills.

·        Strong understanding of lean manufacturing principles and process improvement methodologies.

 

Key Competencies:

·        In-depth knowledge of the FIBC production process, including tapes, looms, and finishing stages.

·        Proficiency in calculating BOM and understanding the cost structure of FIBC bags.

·        Ability to train and upskill workers, ensuring smooth rotation and workforce flexibility.

·        Strong focus on quality, efficiency, wastage reduction, and cost control.