PLANT HEAD

Company Overview

Sundaram Steels Pvt Ltd is an integrated steel manufacturer with an installed capacity of 700 MTPD for Sponge Iron (DRI), 600 MTPD for MS Billets, and an 18 MW Captive Power Plant (waste heat recovery). The company has an annual revenue of approximately ₹700 Crore and operates as a fully integrated value chain from DRI to finished billet.

Job Summary

The Plant Head is responsible for the unified operational leadership of all manufacturing and maintenance functions at the plant. This role ensures that the DRI, SMS, and CPP units operate as a coordinated, interdependent system - maximizing production output, equipment availability, and operational efficiency while driving a culture of safety, discipline, and continuous improvement. The Plant Head serves as the single point of operational accountability between the Managing Director and all plant-level General Managers.

Responsibilities

• Production Coordination & Output

  • Coordinate daily and monthly production planning across DRI, SMS, and CPP to optimize throughput and inter-unit material flow.
  • Monitor DRI-to-Billet conversion yield and minimize transition losses between units.
  • Ensure DRI capacity utilization consistently targets 100%+ (vs. 700 MTPD installed).
  • Drive SMS billet output to rated capacity of 600 MTPD with optimal heat size and casting efficiency.
  • Oversee CPP operations to ensure 18 MW power availability, reducing dependence on grid power.
  • Review daily production Management Information Systems (MIS) and take corrective actions proactively.

• Maintenance & Equipment Reliability

  • Partner with GM – Maintenance to implement a robust Preventive & Predictive Maintenance (PPM) programme across all units.
  • Drive improvement in Overall Equipment Effectiveness (OEE) across critical equipment — rotary kiln, ESP, CCM, turbo-alternator.
  • Target reduction in unplanned shutdowns; improve planned vs. unplanned downtime ratio.
  • Ensure capital spares planning and inventory management to avoid production losses.
  • Review and approve major maintenance schedules, annual shutdowns, and capital repair plans.

• Operational Efficiency & Cost Control

  • Monitor and improve specific consumption benchmarks: coal per tonne of DRI, power per tonne of billet, refractory life.
  • Identify and eliminate operational waste, idle time, and rework across all units.
  • Collaborate with procurement on raw material quality (iron ore, coal, dolomite) that impacts process efficiency.
  • Drive fuel and power cost reduction initiatives in coordination with the CPP team.

• Team Leadership & GM Coordination

  • Provide daily operational direction to all four GMs — Production (DRI), Production (SMS), Production (CPP), and Maintenance.
  • Facilitate cross-functional resolution of bottlenecks impacting production flow.
  • Build a performance-driven culture: set targets, review performance, and develop managerial capability.
  • Manage large contract and permanent workforce; maintain industrial relations and discipline.
  • Conduct structured shift reviews, daily Head of Department (HOD) meetings, and weekly production review meetings.

• Safety, Environment & Compliance

  • Champion plant safety culture — zero Lost Time Injury (LTI) as a non-negotiable standard.
  • Ensure compliance with the Factories Act, PCB norms, MOEF guidelines, and other statutory requirements.
  • Drive implementation of safety Standard Operating Procedures (SOPs), incident investigation, and near-miss reporting systems.
  • Liaise with statutory inspectors, pollution control authorities, and auditors as required.

• Reporting & Management Interface

  • Prepare and present weekly/monthly operational performance reports to the Managing Director.
  • Flag operational risks, capacity constraints, and equipment issues with timely escalation.
  • Participate in strategic reviews when production capacity, capital expenditure, or expansion is on the agenda.

Qualifications

• Educational Background

  • B.E. / B.Tech in Metallurgy, Mechanical, Electrical, or Chemical Engineering (mandatory).
  • MBA / PGDM in Operations Management (preferred, not mandatory).

• Experience

  • 20 – 25 years of experience in steel/metals manufacturing.
  • Minimum 5 years in a Plant Head, VP-Operations, or Sr. GM-Operations role.
  • Hands-on experience in DRI/Sponge Iron plant operations is essential.
  • Working knowledge of SMS (billet/CCM) and CPP operations strongly preferred.
  • Experience managing large, multi-shift manufacturing workforce.

Preferred Skills

• Industry background in mid-size integrated steel plants (e.g., JSPL, Sarda Energy, Godawari Power, Shyam Steel, Rungta, Nav Bharat).
• Candidates from DRI-based integrated plants will be given preference.

Experience

• 20 – 25 years in steel/metals manufacturing with specific experience as Plant Head or similar leadership roles.

Environment

The role will be based at the plant site in Bokaro, Jharkhand, requiring on-site presence for operational management.

Salary

Fixed CTC of ₹ 35 – 55 LPA (commensurate with experience).

Growth Opportunities

Potential career advancement to higher executive roles within the organization, contingent upon performance and organizational growth.

Benefits

• Performance bonus of 15 – 25% of Fixed CTC, linked to production and efficiency KPIs.
• Perquisites including company accommodation, vehicle/conveyance, and medical insurance.