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Production Manager - Cement Plant

FL Smidth Private Limited
10 - 20 yrs
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At par with market standard, best in the Inductry Openings: 1 Posted 11 days ago Job Applicants: 618 Job Views: 1143

Job Description

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    Job Summary
    The Production Manager has direct ownership of the production budgets within the plant, with all production operations, production targets /day to day site management/production planning. It is the Production Manager responsibility to ensure that the plant is operated to the process and quality targets. Responsible for the continued improvement culture and implementation of the Plants production improvement program and the application of operational techniques to develop proactive behavior. Responsible for the setting and control of the operating standards for the consistent and effective operation of all the major process workshops.

    Duties and Responsibilities


    Ensure compliance with the relevant statutory legislation and internal company Safety, Health & environmental standards
    Communicate clearly on information relating to potential dangerous situations and get confirmation that they are correctly understood.
    Make sure key equipment is working properly.
    Ensure the use of PPE.
    Check safety & housekeeping in the workplace

    Production Activities
    Develop, maintain & ensure compliance of Standard Operating Procedures for entire production plant from raw materials to final product.
    Define the long-term plan & develop and implement the department continuous improvement program as part of the overall business improvement program.
    Develop annual, daily, production plan and adjust plan if required.
    Schedule and organize shift teams to ensure execution of the production plan
    Prepare the annual plan and budgets for the production function as part of the annual planning process.
    Drive improvements in plant availability and performance, including costs, by the implementation of operational best practices across the whole site.
    Liaise between functions to ensure consistency, coordination and best practice to eliminate losses from poor practices, expedite learning, etc.
    Ensure that production staff operate the plant to the standards set by the process and quality departments.
    Ensure stable operation and product quality.
    Actively manage & liaising with FLS O&M supply chain with regard to production spare parts & consumables, as well as with the client with regard to supply of raw materials.
    Set efficient communications with the clients sales team and secure to ensure efficient processing of orders and management of customer vehicles
    Ensure full participation in the application of Defect Elimination / Root Cause Failure Analysis.
    Management site manufacturing systems (PXP/ECS) to maximize their potential to the organization.
    Provide daily, weekly and monthly operation records in conjunction with process & quality departments.
    Assess variances to budget, identify causes and implement remedial actions.
    Report on daily basis the material movement (open-in-out-close) from raw materials to final product (stock levels for each process area).
    Allocate production staff to support the Quality Department in the collection of samples for quality analysis
    Coordinate the program of inspection & repairs with the maintenance department.
    Manage & coordinate with maintenance & other departments the production annual plan and shutdown activities.
    Coordinate with maintenance function to ensure the key maintenance work is scheduled to provide maximum utilization of maintenance resources (Staff & spare parts & equipment)
    Plan shutdowns with other departments.
    Contribute to maintaining equipment in good condition by complying with instructions of use & by regular monitoring of equipment, including cement storage silos and by warning the maintenance department if required.
    Develop Process Measurement Plan for daily, weekly, monthly and annual process measurements.
    Develop master plan for Mill audit

    Team Management

    Define the mission & objectives of his staff and conduct PDR sessions
    Development of production staff by developing IDP's, defining skill gaps, and where necessary, providing training in activities that support production improvement and coaching.
    Develop succession plan for production department & ensure successors for key positions.
    Promote quality of work and motivates his staff.
    Implement daily, weekly, monthly plant operation practices & cross functional coordination.
    Prepare the plant organization & People review, including the Plant Team Assessment.

    Performance Criteria

    Guarantee the safety of the equipment and of the people working with him.
    Guarantee the compliance with FLSmidth environmental standards in his field of activities.
    Respect production plant commitments in terms of volumes, deadlines, costs & quality compliance.
    Ensure production team performs correctly.
    Ensure good atmosphere and coordination with his team.
    Guarantee the safety of the equipment and of the people working with him.
    Guarantee the compliance with FLSmidth environmental standards in his field of activities.
    Achieve budget.

Salary: At par with market standard, best in the Inductry

Industry: Construction / Engineering / Cement / Metals

Functional Area: Production , Manufacturing , Maintenance

Role Category:Production/Manufacturing/Maintenance

Role:Quality Assurance/Quality Control Manager

Employment Type: Permanent Job, Full Time


Desired Candidate Profile


    Engineering Degree with majors in Mechanical, Electrical, Chemistry or Process
    Safety Qualification - NEBOSH, or IOSH, or any other international certification).
    Major - Mechanical, Production or Chemistry
    Safety skills,

    Knowledge and specific Experience

    10 Year experience in Cement Industry (Holcim, FLSmidth O&M, Cemex, etc.)
    2 Years as Plant Manager or Operations Manager or Deputy Plant Manager. Good understanding of the function; KPIs, Meetings, Reports, Safety, Environment, Quality, Maintenance, HR, Procurement, Production, Process, etc.
    Experience in managing of Plant KPIs, Strategic Planning, Budget, management of contingencies, Customer Service, Risks, ISOs, Training, Procedures, Continuous Improvement systems, costs, etc.
    Experience in management and promotion on of health and safety.
    Process Engineering Experience at a senior level within the Cement Industry
    Demonstrated Plant Mastery Experience of Cement Grinding, Grinding major & auxiliary equipment (Ball Mills & major equipment process audits)
    Understanding of environmental legislation.
    Thorough understanding of the cement manufacturing process
    Understanding and use of KPIs relating to the cement manufacturing process.
    Involvement in Continuous Improvement techniques
    Comprehensive knowledge with the standards and characteristics for final product and its quality.
    Production planning, setting and controlling departmental budgets
    Management of a continuous operation and management of shift teams
    Ability to identify training needs and provide coaching to staff.

    Interpersonal & Management Skills

    IT Literate, particularly with ERP and Microsoft applications
    Ability to communicate with people at all levels (Fluent English, speaking, writing, reading).
    People Management Skills
    Presentation Skills
    Excellent communication skills


UG: Any Graduate - Any Specialization, B.Tech/B.E. - Any Specialization, Chemical, Mechanical, Electrical, Diploma - Any Specialization, Chemical, Electrical, Mechanical, B.Sc - Any Specialization, B.Com - Commerce

Company Profile:

FL Smidth Private Limited

FLSmidth is an international engineering company with an annual turnover of EUR 2.6bn. We are the world’s leading supplier of plants, machinery, services and spare parts to the cement and minerals industry. To maintain our market leading position, we invest massively in technological innovation, R & D and training of our 10,800 employees worldwide. Visit for further information on our business and services.
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Rajesh Company HR FL Smidth Private Limited Chennai

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