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Plant Head – Blown Film & Thermoforming Manufacturing Plant
Plant Head – Blown Film & Thermoforming Manufacturing Plant
22
Vapi
Job Views:
Created Date: 2026-05-15
End Date: 2026-07-13
Experience: 12 - 20 years
Salary: 1199998
Industry: Others
Openings: 1
Primary Responsibilities :
Job Description
Plant Head – Blown Film & Thermoforming Manufacturing Plant
Position Details
Position Title: Plant Head – Blown Film Manufacturing
Location: Vapi
Reporting To: Director
Job Summary
The Plant Head will be responsible for overseeing overall plant operations, production efficiency, quality assurance, maintenance, safety compliance, and profitability of the blown film and thermoforming manufacturing facility.
The role requires strong leadership in managing production teams, optimizing machine performance, reducing wastage, improving operational efficiency, and driving continuous improvement initiatives across the plant.
Experience Requirements:
Key Responsibilities
Production & Operations
Lead end-to-end plant operations for blown film extrusion and thermoforming processes
Ensure achievement of daily, weekly, and monthly production targets
Monitor machine productivity, OEE, downtime, wastage, and energy consumption
Optimize production planning and execution for timely order fulfillment
Improve extrusion output, gauge control, bubble stability, and film quality consistency
Ensure efficient utilization of raw materials, manpower, and utilities
Technical & Process Management
Supervise mono-layer and multi-layer blown film extrusion operations
Troubleshoot extrusion-related process issues including:
Gauge variation
Bubble instability
Gel formation
Die lines
Blocking/slipping issues
Thickness inconsistency
Coordinate preventive and breakdown maintenance activities
Implement process improvements to reduce scrap and improve productivity
Quality Control
Ensure adherence to customer specifications and quality standards
Coordinate with QA/QC teams for testing and process validation
Reduce customer complaints and rejection rates
Maintain compliance with ISO, BRC, FSSC, and applicable quality standards
Maintenance & Engineering
Ensure effective preventive maintenance implementation
Improve machine uptime and reduce breakdown frequency
Coordinate installation and commissioning of new machinery and equipment
Monitor utility performance and operational reliability
Team Management
Lead production, maintenance, quality, and warehouse teams
Conduct manpower planning, training, and performance reviews
Build a culture of accountability, discipline, and continuous improvement
Mentor supervisors and shift teams for operational excellence
Safety & Compliance
Ensure compliance with EHS and statutory regulations
Promote safe operating practices across the plant
Ensure adherence to labor laws, factory regulations, and pollution control norms
Conduct regular safety reviews and corrective action implementation
Cost Control & Continuous Improvement
Monitor and control manufacturing costs
Improve operational profitability and efficiency
Track consumption norms for polymers, masterbatch, and utilities
Drive Lean Manufacturing, 5S, Kaizen, TPM, and continuous improvement initiatives
Required Qualifications
Bachelor’s Degree / Diploma in:
Plastic Engineering
Polymer Engineering
Mechanical Engineering
Related Technical Field
MBA Operations preferred
Experience Required
12–20 years of experience in plastic processing or blown film manufacturing
Minimum 5 years in a senior plant leadership role
Strong expertise in:
LDPE
LLDPE
HDPE
Multilayer film production
Experience in flexible packaging and high-speed blown film lines preferred
Required Skills
Strong technical expertise in blown film extrusion processes
Production planning and process optimization
Leadership and team management
Problem-solving and analytical skills
Knowledge of extrusion machinery and maintenance practices
ERP/MIS reporting knowledge
Strong communication and decision-making abilities
Key Performance Indicators (KPI/KRA)
| KRA | KPI | Target Benchmark |
|---|---|---|
| Production Management | Production achievement vs plan | ≥ 95% |
| Machine utilization | ≥ 85% | |
| OEE | ≥ 75–85% | |
| Quality Control | Customer complaints | < 1% |
| Rejection rate | ≤ 2% | |
| First-pass quality approval | ≥ 98% | |
| Wastage & Cost Control | Process scrap/waste | As per target |
| RM consumption variance | Within standard norms | |
| Power consumption per kg | Reduction trend | |
| Maintenance & Reliability | Preventive maintenance compliance | ≥ 95% |
| Utility uptime | ≥ 98% | |
| Planning & Dispatch | OTIF Dispatch | ≥ 95% |
| Safety & Compliance | Lost Time Injury (LTI) | Zero |
| PPE Compliance | 100% | |
| Statutory compliance | Zero non-compliance |
Work Environment
Manufacturing plant environment
Leadership role involving cross-functional coordination
Fast-paced production and operations setup