Plant Manager - Aluminium Wire Rod and Conductor

Company Description

Masters India,  44 year old group, which is into Manufacturing, Healthcare, Hospitality and IT with an aggregate turnover of INR 1000+ crores. We are expanding rapidly and are, therefore, looking for leaders to help the company achieve its goals. We are expanding rapidly and are, therefore, looking for leaders to help company achieve its goals.

Job Description

The Plant Manager will be responsible for leading all operations of the Aluminium Wire Rod and Conductor manufacturing unit. The role requires strong technical expertise in aluminium metallurgy, casting, rolling, drawing, and stranding processes, along with proven leadership in productivity, cost optimization, and quality assurance.

Key Responsibilities:

1. Production & Operations

• Oversee continuous casting, rolling mill, rod breakdown, and conductor stranding operations.
• Ensure adherence to production schedules, quality parameters, and plant utilization targets.
• Optimize metal yield, energy efficiency, and throughput.
• Plan alloy changeovers (EC Grade, AL59, STAL, 6201, etc.) to minimize downtime.
• Implement lean manufacturing and TPM practices.

2. Maintenance & Technical

• Supervise preventive and predictive maintenance of melting furnaces, holding furnaces, CCR lines, and drawing machines.
• Coordinate with engineering teams for equipment upgrades, automation (PLC/SCADA), and process improvements.
• Ensure uptime targets (>90%) through robust maintenance planning.
• 3. Quality & Process Control
• Supervise preventive and predictive maintenance of melting furnaces, holding furnaces, CCR lines, and drawing machines.
• Coordinate with engineering teams for equipment upgrades, automation (PLC/SCADA), and process improvements.
• Ensure uptime targets (>90%) through robust maintenance planning.
• 3. Quality & Process Control
• Drive continuous improvement in rod and conductor quality – tensile strength, resistivity, elongation, and surface finish.
• Coordinate with QA team for metallurgical testing, spectrometer calibration, and ISO/QMS compliance.
• Implement statistical process control (SPC) for critical process parameters.

4. Safety, Environment & Compliance

• Ensure full compliance with EHS standards, pollution control norms, and statutory audits.
• Drive a culture of zero-incident operations.
• Coordinate with external agencies for environmental and energy audits.

5. People Management

• Lead, train, and motivate production and maintenance teams across all shifts.
• Build team capability through skill matrix tracking and training programs.
• Foster collaboration between production, maintenance, and planning teams.

6. Cost Control & Reporting

• Monitor OPEX, energy consumption, yield losses, and manpower efficiency.
• Coordinate with SCM and Finance for material planning, inventory control, and cost analysis.
• Prepare monthly MIS reports on production, rejection, and KPIs.