Job Description – Plant Manager

Key Responsibilities

• Manage day-to-day operations of RC Refinery, Glycol, Coolant, and Brake Fluid manufacturing plants, ensuring smooth and efficient plant performance.

• Plan, organize, and control production activities, manpower, raw materials, utilities, and plant resources to achieve production targets.

• Oversee preventive, predictive, and breakdown maintenance of rotary and static equipment, including pumps, heat exchangers, reactors, agitators, mechanical seals, centrifuges, compressors, boilers, thermic fluid heaters, chillers, cooling towers, and related equipment.

• Ensure reliable operation of refinery units, distillation systems, reactors, blending systems, filling lines, storage tanks, pipelines, and utility facilities.

• Develop and implement maintenance procedures, inspection plans, equipment reliability programs, and condition-monitoring systems.

• Lead plant engineering projects, equipment installation, commissioning, plant modifications, capacity expansion, and process improvement initiatives.

• Prepare and control annual operating and maintenance budgets, capital expenditure plans, and cost-reduction programs.

• Monitor production efficiency, equipment availability, energy consumption, downtime, maintenance costs, and other key performance indicators (KPIs).

• Ensure compliance with Standard Operating Procedures (SOPs), quality standards, environmental requirements, occupational health and safety regulations, and applicable statutory requirements.

• Participate in HAZOP, Pre-Startup Safety Review (PSSR), and Management of Change (MOC) activities to ensure safe plant operations.

• Implement maintenance excellence programs, including Total Productive Maintenance (TPM), Failure Mode and Effects Analysis (FMEA), root cause analysis, and continuous improvement initiatives.

• Ensure product quality and process control in Glycol, Coolant, Brake Fluid, and refinery operations in coordination with the Quality Control and Laboratory departments.

• Coordinate with Production, Maintenance, Laboratory, HSE, Quality, Procurement, Stores, and other departments to ensure uninterrupted plant operations.

• Lead, train, and develop plant personnel, engineers, supervisors, operators, and maintenance teams to improve productivity, accountability, and technical competency.

• Manage equipment inspection, testing, qualification, and documentation requirements for internal and external audits.

• Maintain and utilize computerized maintenance management systems (CMMS), such as SAP PM, Oracle PM, or IBM Maximo, for maintenance planning, work orders, spare parts, and equipment history.

• Lead internal audits and ensure implementation of applicable ISO quality, environmental, occupational health and safety, and energy management systems.

• Ensure optimum utilization of manpower, equipment, utilities, and spare parts while minimizing operational risks and unplanned shutdowns.

• Prepare regular reports on production performance, maintenance activities, equipment reliability, costs, safety, and improvement plans for management review.

Required Qualifications & Experience

• Bachelor’s Degree or Diploma in Mechanical, Chemical, or Industrial Engineering.

• Minimum 10–15 years of relevant experience in chemical, petrochemical, refinery, or process manufacturing industries, with substantial experience in plant operations and maintenance.

• Strong practical knowledge of RC Refinery, Glycol, Coolant, and Brake Fluid manufacturing processes.

• Extensive experience in rotary and static equipment maintenance, plant utilities, mechanical systems, and industrial project execution.

• Proven experience in plant management, production planning, maintenance strategy, cost control, and team leadership.

• Hands-on experience with SAP PM, Oracle PM, IBM Maximo, or similar maintenance management systems.

• Good knowledge of ISO management systems, HAZOP, PSSR, MOC, TPM, FMEA, root cause analysis, and industrial safety practices.

• Strong problem-solving, decision-making, communication, planning, and leadership skills.

Key Competencies

• Plant Operations and Production Management

• Refinery and Chemical Process Knowledge

• Mechanical Maintenance and Equipment Reliability

• Project Planning and Execution

• Budgeting and Cost Optimization

• Quality, HSE, and Statutory Compliance

• Team Leadership and Workforce Development

• Continuous Improvement and Operational Excellence

Performance Indicators (KPIs)

• Achievement of production targets and plant efficiency.

• Equipment availability and reduction in unplanned downtime.

• Product quality and rejection rates.

• Maintenance and operational cost control.

• Compliance with safety, quality, environmental, and statutory requirements.

• Energy and utility consumption optimization.

• Timely execution of maintenance and capital projects.

• Manpower productivity and implementation of continuous improvement initiatives.