Job Description

Senior Manager / AGM - Plant Operations
Department: Manufacturing / Operations / Quality
Employment Type: Full Time
Location: India
Reporting To: Anoop Agarwal
Description
To lead, plan, and manage all aspects of setting up, operating, and continuously improving a manufacturing facility producing oil-filled submersible motors. This includes engineering design (including reverse engineering), plant layout, value engineering, production management, and in-process quality assurance to achieve targets in safety, cost, delivery, reliability, and product quality
Key Responsibilities
ESSENTIAL DUTIES AND RESPONSIBILITIES
Facility Setup & Plant Layout

• Lead end-to-end establishment of the manufacturing facility: site selection input, utilities, infrastructure, power, water, HVAC, waste treatment, etc.
• Design plant layout for efficient flow of materials, components, subassemblies, final assembly, testing, packing, and shipping, ensuring safety, ergonomics, minimal material handling, and logical process flow.
• Select and establish workstations, cells, and lines; plan for future expansions.
• Plan for utilities and supporting facilities (oil storage/filling stations, cooling, testing labs, maintenance workshops).

Production Management & Process Control

• Plan, schedule, and oversee all manufacturing operations: stator winding, rotor fabrication, insulation, oil filling, rotor sealing, testing, assembly.
• Implement methods and metrics for productivity, yield, throughput, downtime, capacity utilization.
• Manage tooling, machinery, equipment procurement, installation, commissioning, preventive & breakdown maintenance.
• Oversee resource allocation: manpower, machines, materials, Time, shifts.
• Implement and sustain production planning & inventory systems (e.g., ERP / MRP).

Quality Assurance & In-Process Quality Control

• Define and monitor in-process quality checkpoints, inspections and tests (dimensional, electrical, insulation resistance, leakage, vibration, thermal performance, etc.).
• Ensure final product meets required performance, durability, compliance (standards / certifications) and reliability.
• Implement root cause analysis for rejects, nonconformances; corrective & preventive actions (CAPA).
• Ensure process stability using statistical process control (SPC), control charts, Poka-yoke, etc.
• Oversee calibration of instruments, testing lab, etc.

Advance Engineering & Reverse Engineering

• Oversight of engineering functions to design motor components, assemblies, tooling and fixtures.
• Lead reverse engineering initiatives where required: analyzing competitor or customer motors, remanufacturing or redesigning for performance, reliability, cost reduction.
• Ensure up-to-date engineering drawings, BOMs, tolerances, specifications, and change control in place.
• Interface with R&D / design engineers to ensure manufacturability (DFM), maintainability and robustness.

Value Engineering

• Identify cost reduction / value enhancement opportunities in materials, designs, processes while maintaining or improving performance, reliability, and safety.
• Evaluate alternative suppliers, substitute materials, optimize component designs.
• Apply techniques like life-cycle costing, cost-benefit analysis, benchmarking.
• Implement continuous improvement programs (Kaizen, Lean, etc.) to reduce scrap, rework, waste, cycle times.

Supply Chain & Materials Management

• Source raw materials, components, spares, including evaluation of vendors.
• Ensure material quality and timely deliveries to meet production schedules.
• Inventory management: raw material, WIP (work-in-progress), spare parts.
• Minimize holding costs and avoid material obsolescence.

Continuous Improvement & Technology Upgrades

• Deploy Lean, Six Sigma, 5S, SMED, value stream mapping, etc.
• Monitor technological trends (e.g. improved insulation, oil formulations, motor efficiency) and assess adoption.
• Use data analytics, production metrics, root cause problem solving to improve yield & reduce cost.
• Benchmark vs industry best practices.

Safety, Environment, Health & Regulatory Compliance

• Ensure plant operations comply with safety, environmental, health regulations.
• Implement PPE, safe handling of oil, chemicals, electrical hazards, fire safety.
• Maintain environmental permits, oil spill control, waste oil treatment/disposal.
• Drive safety culture including training, audits, hazard identification and mitigation.

Budgeting, Cost Control & Financial Performance

• Prepare capital expenditure (CapEx) plans (machinery, tooling, test equipment, facility infrastructure).
• Prepare operational budget, monitor vs actuals: labor, materials, utilities, maintenance.
• Monitor cost per unit, cost overruns, implement cost saving measures.
• Manage supplier costs, material consumption, yield losses.

Leadership & Human Resources

• Recruit, train, develop technical and shop floor teams: engineers, technicians, operators.
• Set clear performance goals: safety, quality, productivity, cost.
• Drive culture of continuous improvement, accountability.
• Oversee shift supervision, cross-department coordination (engineering, quality, maintenance, procurement, R&D).

Skills, Knowledge and Expertise
Technical / Engineering Skills

• Degree in Mechanical / Electrical / Industrial Engineering (or equivalent), plus strong hands-on experience in motor manufacturing or heavy electromechanical equipment.
• Experience with advanced & reverse engineering: reading, preparing, verifying technical drawings; 3D modelling/CAD; measurement tools; design for manufacturability (DFM).
• Knowledge of materials used: metals, insulation materials, sealing materials, oil types, etc.
• Understanding of processes specific to oil-filled submersible motors: stator/rotor winding, impregnation, oil filling, sealing, balancing, testing under submerged or sealed conditions.

Process / Manufacturing Skills

• Process engineering: process flow mapping, bottleneck analysis, plant layout design.
• Value engineering / cost-reduction mindset.
• In-process quality control, SPC, test & measurement, reliability engineering.
• Maintenance engineering: preventive, predictive maintenance, equipment reliability.

Management & Leadership

• Proficiency in setting up a facility: operations, staffing, process documentation, SOPs.
• Strong planning & organizational skills.
• Leadership and people management: coaching, mentoring, performance management.
• Cross-functional collaboration (with design/R&D, procurement, quality, logistics).

Communication

• Delivers accurate, clear, and concise messages orally and/or in writing.

Problem Solving

• Uses a logical, systematic search for the source of a problem, determining the most likely cause by eliminating potential causes of a problem.

Decision Making

• Identifies and understands issues, problems, and opportunities; compares alternatives and makes timely decisions.

Project Management

• Develops project plans, schedules and budgets, and keeps project team on task. Manages risks and issues. Prepares and delivers project status reports.

Education and Experience

• Bachelor's degree in mechanical / electrical / industrial engineering. A master's or specialized qualification is a plus.
• Experience of 13 - 17 years in manufacturing operations, preferably in motor/electrical machinery or comparable heavy equipment. For a new facility setup, prior experience in commissioning/greenfield projects is highly preferred.
• Demonstrated experience in reverse engineering, value engineering, plant layout, process quality, setting up production lines, leading from design to full production.
• Familiarity with continuous improvement methodologies (Lean, Six Sigma, etc.)

Work Location

• Vadodara & Ahmedabad
• (The selected candidate will initially be based at Vadodara, Gujarat. After successfully transitioning into the role, they will be required to move to Ahmedabad, Gujarat to oversee the greenfield project for establishing a new manufacturing facility)

Skills Required