Job Description -

Name

Designation Head Operations

Department Operations

Location Bhiwadi

Reporting to

Reported by

Key Responsibilities

Operational  Ensure Achievement of Business Plan from Operation side of Plant, keep regular track of
Excellence production and costs and take corrective actions whenever there is any deviation to ensure
all targets are achieved as defined in Business Plan
 Work with Plant Head and production teams and do periodic materials planning and
ensure there is no loss of production and man-day’s due to unavailability of RML and
other materials supply
 Strictly monitor chemical usage and ensure that the usage is as per standards
 Develop and manage internal & external processes and functions to support the Plant,
without losing sight of the imperative to continuous growth and scaling the organization in
an aggressive manner for next levels of performance
 Keep control on Operative cost of Plant to ensure better gross margin and profitability
through enhancement of processes, cost optimization projects and innovation
 Building and execution of an effective supply chain management model to sustain tenacity
of aggressive business growth requirement of Plant
 Implement robust Production Planning and Control to ensure sustainable production for
continuous supply of Lead Alloys as per the sales indent, customer demand and market
trends and also assure there is no revenue loss due to the production in Plant
 Drive Quality standards and measures to improve the quality of lead alloys manufacturing
system/process in plant and ensure we are following the best practices used in global lead
manufacturing standards
Productivity  Develop production plans based on sales orders and ensuring accomplishment of targets as
Management per business plan
 Reviewing daily production of each section (BBSU, Smelting and Refining) and taking
corrective measures wherever necessary to ensure timely accomplishment of production
targets
 Checking Actual production against company standards and taking corrective actions
where ever and whenever required
 Close monitoring on fuel and consumables to optimize cost of production and ensure cost
of production is not exceeding than the predefined standards and there is no compromise
on desired quality standards.
 Drive continuous improvement and cost reduction projects: mentoring & enabling
execution of Lean manufacturing and Kaizen projects for elimination of business irritants
and non-value added process
Industrial  Regular analysis on available machineries in BBSU, Rotaries in smelting and pots in
Engineering refining and if required recommend for new machines/equipment’s and renovation and
modification of existing machines/equipment’s.
 Define production processes stage wise and do lay out designing of plant, to ensure
optimum production with less production cycle time and manpower requirements
 Define Preventive maintenance plan and ensure rigorously plan has been adhered with
proper MIS on health of all machineries
 Organizing the repair and routine maintenance of production equipment and ensure there
is no loss of Production because of Equipment or Machine Breakdown
 Guide and help project and maintenance team to install and commission new machines
and equipment’s as per the lay out, design and functional requirements
Manpower  Work on daily, monthly and yearly workforce planning and recommend required quality
Optimization manpower
 Conduct manpower cost analysis and ensure manpower cost is under control
 Close Monitoring of Casual and Contractual Work Force numbers as per production
norms
 Tracking of manpower numbers, sections and segment wise and do optimization of
existing manpower before recommending change
BBSU and Manual  Ensure sufficient stock of scrap battery availability for continues production as per
cutting production plan
 Ensure material is stacked and used separately according to its type and proper calculation
is done separately for each type
 Ensure BBSU production and Manual cutting production is as per plan
 Ensure the recovery (plate, grid, fine grid and paste) and moisture in paste is as per
standards
 Ensure material input to the BBSU section is matching with total output (plastic, plate,
grid, fine grid and paste)
 Ensure all the log sheets are properly filled and signed by the concerned persons
 Ensure preventive maintenance is scheduled is made and adhered
 Ensure minimum breakdown of BBSU and ensure breakdown time is recorded properly
Smelting  Ensure sufficient stock of lead material (plate, grid, fine grid and paste) and charging
material (charcoal, soda ash, mill scale, cast iron, lime stone etc) availability for continues
production in rotaries as per production plan
 Ensure rotary production is as per plan
 Ensure material and fuel consumption is as per standards
 Ensure the recovery from the rotaries is as per standards and in case there is any deviation
try to find out reasons and take corrective actions
 Ensure material input (lead material from BBSU section & manual cutting and charging
material) in smelting section matches the output (Block, slag and flue dust)
 Ensure Batch and cycle times are as per standards
 Ensure slag is segregated and stored properly and slag with more than standard lead
content is recycled in rotary
 Ensure all the log sheets are properly filled and signed by the concerned persons
 Ensure preventive maintenance is scheduled is made and adhered
 Ensure minimum breakdown of rotaries and ensure breakdown time is recorded properly
Refining and  Ensure sufficient stock of Raw Material (RML Block from Rotary, RML ingots and
Packing Master Metal ingots) and critical chemicals (Arsenic, Selenium, Silver etc.) is always
above minimum inventory level
 Ensure refining production is as per plan
 Ensure material and fuel consumption is as per standards
 Ensure the recovery from the refining is as per standards and in case there is any deviation
try to find out reasons and take corrective actions
 Ensure material input (RML Block from Rotary, RML ingots and Master Metal ingots) in
smelting section matches the output (Finished Good, Bad Ingots, skimming, scrap etc)
 Ensure cycle times are as per standards
 Ensure all the log sheets are properly filled and signed by the concerned persons
 Ensure minimum breakdown in refining section and ensure breakdown time is recorded
properly
 Ensure Packing is done as per company standards and as specified by the customer
 Ensure packed material is available as per dispatch plan
 Ensure Packing is done in time and there is minimum inventory of unpacked finished
goods
Production Quality  Implement different verticals of Manufacturing Excellence, including vertical for
technical quality, Environ Management (EHS), TQM and Production Process
Management
 Execute production quality standards, create awareness and set periodic target to improve
and monitor the outcome
 All quality standards are adhered on production floor in consultations with Quality
department and there is no NC in internal and external audits
Environment Health  Ensure all safety equipment are placed as per the standards and statutory compliances
& Safety  All Health, Safety and environment related certification have been completed and there is
 no NC during any internal or external audits.
 In coordination with Plant HR and Admin conduct regular awareness session to educate
production floor workers and relevant staffs to avoid any accidents due to negligence and
lack of awareness
 Ensure sufficient availability of personal protection equipment (PPE) in plant and ensure
all the people on production are using them (especially mask, helmet and safety shoes)
 Inspect and evaluate the equipment and processes related to pollution/environment in
working areas to ensure compliance with government safety regulations and industry
standards.
 Ensure all compliances of Pollution Control Board are met properly and there is no NC
found in Internal or external Audits and there are no complaints.
MR Management  Ensure proper Implementation of ISO Standards in the Plant
 Ensuring proper preparation of documents for ISO Audits and other Certifications
(including fire and safety)
 Ensuring awareness and training sessions of ISO standards and other Certifications are
done regularly among employees
 Ensuring the compliance of all the functions as per the ISO standard
 Conducting Internal Audits and making nonconformity reports
 Measuring & Monitoring the process performance
 Initiate necessary corrective and preventive action
 Review of Quality policy periodically Time to time review of all the functions, to check
the effective implementation of Quality Management system.
 Ensuring removal of open points mentioned in Corrective Actions Required list by
Auditors during any Audit
People Management  Manage workforce and build harmonious working environment on production floor for
better productivity
 Review and measures individual performance on regular basis and reward good performer
and initiate performance improvement plan for below average performer.
 Drive Kaizen, 5’s and other innovative system to improve performance of individuals.
 Identify skills set and skill gap of individual and impart regular coaching and training to
cope with standard performance benchmark and strive to take each individual
performance at next level

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Pilot industries Limited is a ISO 9001, 14001 certified company is a Leading manufacturer of Refined Lead (Pure Lead), Lead
Alloys, Lead Oxide and Lead Acid Batteries (Brand “Leader”), Battery Plates,

Pure Lead Ingot is being produced from Remelted lead, Lead Scraps, and Secondary Lead Ingots though Pyrometallurgical
process. All our Lead products are supplied with Spectrophotometer test reports.

Lead alloys manufacturing plant is located in Bhiwadi Rajasthan and Pant Nagar Uttrakhand. We create lead-antimony alloys,
lead-tin alloys, lead copper alloys, lead cadmium alloys, lead selenium alloys and other alloys as per the requirement of the
customer.

It was founded by Shri Dwarka Prasad Agarwal in the year 1969. Initially it was started as a trader in Battery’s Components &
Raw Material.

Ardee Industries Based in Nellore, moajorly focus is on recycling lead batteries along with an array of lead-based products like
Lead sheet, bricks, powder, etc.
The Unit has installed capacity in Smelting of 12,000 MT/ Annum (Remelted lead) and 24,000 MT/ Annum (Pure Lead and
Lead Alloys) for Refining.
The Unit has 2 Rotaries of 10 MT capacity each and 4 Refining Pots of 25 MT capacity each to achieve the per Annum
deliverables.

Pilot Industries Limited is a leading producer of Refined Lead & Lead Alloy Ingots in India, which are produced by recycling
secondary lead battery scrap (ISRI- RAINS). The company collects local lead battery scrap and imports used battery scrap
from various locations around the world. Our lead smelting plant in India is well equipped with advanced technologies
and machinery units like Battery Breaking and Separation, Rotary Furnace, Lead Refining and Alloying Pots, Casting,
OES spectrometer, etc.

Our state-of-the-art manufacturing substantiates stringent environmental norms in totality. Recycling of secondary lead, old
used battery scraps, lead scraps like wheel weights, lead cable sheathings & smelting of lead concentrates, is carried out
to produce pure lead and alloys.

Pilot has made a mark by offering worldwide recognized products that meet international standards. Pilot has an installed
capacity to produce around 6000 Metric tons of Lead & Lead Alloy Ingots per month.
At PIL we utilize advanced & environmental friendly technology for recovery of Lead metal from Lead Ores / Lead
Concentrates, Lead waste and scrap. Our Recycling Operations consist of battery crushing, separation, Smelting and
Refining Process.

Lead smelting is conducted under the controlled conditions in oil-fired Rotary Furnace with automatic burner, exhaust from
back end to quenching tank and finally to cyclone and bag-house. The entire chain system from furnace to chimney is
maintained under pressure to prevent from fugitive emission.

Fugitive emission which can arise during taping of the metal and slag, is controlled by providing cover with a hooded area
around the furnace. All dust collected in the bag house is recycled to the furnace in certain composition to recover the lead
metal.

Alloying and Refining Pots

Refining: Smelted lead produced from the furnace is refined to final finished products in fully automatic heated oil-fired
kettles covered with the hood and connected to sanitary bag house to collect the dust, if any from fugitive fumes emitted
during the process.

Molten metal at various stages is analyzed in depth to ensure desired chemistry and homogeneity of all elements as per
specified range. After getting laboratory permission & certification, Molten metal is poured into ingot moulds where unique
batch codes are marked on it to ensure complete traceability.

battery breaking and separation unit

Rotary Furnace
Ingots are strapped in Fork lift-able bundles & properly color coded to ensure easy identification & then shipped. The
technology is well developed to suit customer requirements in environment friendly manner, of course competitive and
complementary.

Pilot Industries Limited is a leading Manufacturers and Suppliers of [Link] offers an efficient range of
Automotive Battery, Inverter Tubular Battery, E Rickshaw Battery, Solar battery and plates. We are known for
consistent quality standards,

Pilot Group is India’s best battery manufacturer company. We are proud to introduce ourselves as manufacturer & supplier of
batteries in India with the brand name “LEADER” .We are an ISO 9001 : 2015 and 14001:2015 certified company based in
Delhi since 1969 having manufacturing facility at Pant Nagar (Uttarkhand) with the installed capacity of 6,00,000 batteries per
annum.

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Lead is refined by the process of liquation. Used for low-melting metals (they have low melting points), liquation involves
heating the impure sample. The metal component gets liquefied first and is made to flow down a hearth whereas the impurities
are left behind (at the top).

What is the process of production of lead?

Unlocking the Process: How Lead Ingots are Produced - GME ...
Lead ingots manufacturing process
Pre-treatment: The first step involves collecting and sorting used lead-acid batteries, which are typically sourced from
automotive, industrial, and stationary applications. ...
Breaking and separation: ...
Smelting: ...
Refining: ...
Ingot Production:

How do they manufacture lead?

Plants for the production of lead are generally referred to as lead smelters. Primary lead production begins with sintering.
Concentrated lead ore is fed into a sintering machine with iron, silica, limestone fluxes, coke, soda ash, pyrite, zinc, caustics or
pollution control particulates.
What is the production process of lead?
The principal method of extracting lead from galena, which is its most prominent ore, is done by pyrometallurgical method of
roasting to melting the ore. In other words, the ore is converted to the oxide, and the oxide reduced with coke in a blast
furnace.