Plant Head

Job Purpose

Plan and coordinate resources to achieve high productivity, ensure optimal resource use, maintain operational excellence, and comply with safety and statutory guidelines.

Industry Context and Challenges

The ready-mix concrete (RMC) sector is fragmented and faces intense competition from both organized and local players. Delivering superior service and quality products is crucial to maintain good profit margins. With the growth in infrastructure, there are opportunities to establish new plants. Each plant must operate cost-effectively, maximizing capacity utilization to remain profitable. Employees must remain focused on high performance in their key result areas (KRAs).

Key Responsibilities and Accountabilities

• Address daily customer issues related to cracks, slump control, pumping difficulties, cube failures; implement corrective and preventive measures based on site feedback.
• Design and enforce routine preventive maintenance schedules for plants and machinery; ensure vendors adhere to mandatory safety guidelines and control maintenance costs within budget.
• Manage lifecycle tracking of spare parts.
• Perform physical stock counts and reconcile inventory.
• Prepare, consolidate, and analyze plant plans and budgets.
• Obtain certifications from respective Plant Heads confirming successful commissioning and closure of project gaps.
• Deploy manpower effectively for smooth project pours.
• Optimize transport routes for timely and safe movement of transit mixers (TMs).
• Conduct site appraisals before pours, including evaluating route conditions, matching timing requirements, client measurements, and quality control infrastructure.
• Plan installations of pumps, pipelines, and manage movement of TMs and application engineers for concreting sites.
• Ensure sales targets are met within prescribed price limits.
• Assess equipment backup availability for order execution.
• Monitor batch standard deviations to maintain concrete quality within acceptable limits, taking corrective actions as needed.
• Develop and execute production schedules.
• Conduct daily checks to optimize batching plant and machinery utilization.
• Minimize losses from rejects or cancellations by material diversion or reassigning orders.
• Ensure compliance with statutory regulations by coordinating with relevant government departments, including operational and electrical safety requirements.
• Implement and enforce electrical safety measures such as PPE usage.
• Maintain safety standards around batching plants, including lockout tag out procedures.
• Communicate safety practices with customers and provide support.
• Perform hazard analyses and identify health and safety risks to develop control measures.
• Conduct safety audits as scheduled, including monthly internal audits and equipment evaluations.
• Ensure safety procedures are followed and vendors comply with safety parameters.
• Log safety-related observations and incidents.
• Address environmental pollution concerns from local communities near plants.
• Ensure adherence to environmental and anti-pollution regulations.
• Monitor and control water consumption, energy use, CO2 emissions, dust, particulate matter, and waste output.
• Promote employee development via training, seminars, and conferences.
• Engage in monthly meetings with equipment vendors to enhance resource optimization.