Plant Manager – Heavy Manufacturing (Steel Fabrication & Assembly)
Reports to: Managing Director for the Site
Direct Reports: Production Supervisors, Maintenance Manager, HSE Manager, Quality Manager, Planning/Scheduling, Logistics, and Facilities.
Position Summary
The Plant Manager is responsible for the full operational performance of a heavy-manufacturing facility specializing in welding, machining, steel fabrication, assembly, and industrial coating operations. The role ensures safe, efficient, high-quality production of large steel components used in power generation, industrial heat-transfer systems, and heavy-industry applications.
The Plant Manager drives operational excellence, oversees daily plant activities, manages budgets, develops workforce capability, and ensures compliance with all safety and quality standards.
Key Responsibilities
1. Operational Leadership
- Lead all production activities including welding, machining, plate processing, fabrication, assembly, and surface treatment.
- Ensure on-time delivery of customer projects while maintaining throughput, quality, and cost targets.
- Manage daily/weekly production reviews, KPIs, and performance dashboards.
- Oversee capacity planning, resource allocation, and cross-functional coordination.
2. Health, Safety & Environmental Compliance
- Maintain a strong safety culture and ensure compliance with OSHA / ISO / local regulations.
- Implement and oversee safe-working practices for heavy lifting, welding, pressure equipment, confined spaces, and coating operations.
- Lead incident investigations, corrective actions, and continuous HSE improvement programs.
3. Quality Assurance & Technical Oversight
- Work closely with Quality to ensure all welds, machined parts, and assemblies meet certified standards (AWS, ASME, ISO, EN, customer-specific).
- Promote robust QA/QC processes including NDT (UT, RT, MT, PT), welding qualifications, and inspection protocols.
- Support technical problem-solving and root-cause analysis for defects or process deviations.
4. Continuous Improvement & Lean Manufacturing
- Drive Lean/5S initiatives to improve workflow efficiency and reduce waste.
- Implement standard work, process controls, and visual management systems.
- Introduce automation or robotics where applicable (e.g., robotic welding, CNC improvements).
5. Workforce Leadership & Talent Development
- Lead and develop a team of supervisors, skilled trades, technicians, and engineering support staff.
- Support recruiting of welders, machinists, fabricators, inspectors, and maintenance personnel.
- Build succession plans, training programs (e.g., welding certification), and cross-training initiatives.
6. Budgeting & Cost Management
- Manage operating budget, labor costs, overtime, and capital expenditure planning.
- Identify cost-reduction opportunities and efficiency gains in fabrication, machining, and coating lines.
- Ensure accurate production reporting and financial accountability.
7. Equipment, Facilities & Maintenance
- Oversee preventative maintenance programs for CNC machines, welding robots, plate rollers, burn tables, cranes, and paint/coating booths.
- Ensure plant infrastructure, cranes, lifting equipment, and utilities remain fully operational and compliant.
8. Customer & Stakeholder Engagement
- Collaborate with engineering, project management, and sales to support customer requirements.
- Participate in customer audits, factory visits, and technical reviews.
- Ensure manufacturing feasibility is considered early in design and quotation processes.
Key Skills & Competencies
Technical Expertise
- Strong understanding of welding processes (SMAW, GTAW, GMAW, FCAW), welding certification standards, and structural steel codes.
- Knowledge of machining (CNC milling, turning), plate cutting (plasma/oxy-fuel), rolling, and fabrication processes.
- Experience with heavy fabrication, large assemblies, and high-tonnage lifting operations.
Leadership & Communication
- Strong leadership presence on the factory floor.
- Excellent conflict resolution, coaching, and team-building skills.
- Ability to align cross-functional teams to meet production goals.
Analytical & Operational Excellence
- Skilled in Lean manufacturing, production planning, and workflow optimization.
- Data-driven approach to improving safety, quality, delivery, and cost.
Qualifications & Experience
- Bachelor’s degree in Engineering, Manufacturing, Industrial Technology, or related field (preferred).
- 8–15+ years of manufacturing experience, ideally in heavy steel fabrication or industrial equipment manufacturing.
- 5+ years in a supervisory or managerial role.
- Experience with ISO 9001, ISO 14001, and OHSAS/ISO 45001 systems.
- Familiarity with ASME / AWS welding codes and NDT processes.