I sincerely appreciate the apt suggestions given by Mr. Divekar. At the outset, you have already clarified that the demand for excess manpower is not the real issue. I readily accept this, as the manpower requirement in an ISP is determined after an elaborate and comprehensive study by IED and other allied departments, as well as the technology provider, and is finalized after consultation with the Union. Once the Sanctioned Manpower is fixed, it's difficult to get it enhanced.
Any mid-stream requirement needs to be justified based on additions or modifications in the process or products. The only variable factor can be Contractual Labour deployment for purposes such as cleaning, periodic maintenance, or during capital repairs.
Since manpower is not the issue here, the association of the Manager with the Union and the resulting nuisance-value in terms of general discipline, productivity, and employee morale is the concern.
Manager's Level and Departmental Involvement
You have not mentioned the level/grade of the manager. How is the HOD of CO & CCD treating this matter? What is his opinion? Did he bring this matter to the notice of the Personnel Dept. overtly or covertly? Or, is it just an internal matter within the Personnel Dept.?
In case the matter has not been initiated or is not in the cognition of the HOD, then he should be taken into confidence. As CO & CCD is the first vital link in the production process, the output and quality of Coke and Coke Oven gas would affect all production parameters starting from the Blast Furnaces to downstream Rolling Mills. As such, the HOD should rightly be concerned, and his suggestion and support would be necessary.
Transfer Considerations
You have said that he has been transferred earlier, but the result did not turn out to be good. Where was he transferred to? In a different department or outside the Plant?
Under the circumstances, transfer seems to be a good option as already suggested earlier. In which section is he working? Whether in Production or in Mechanical or Electrical maintenance?
He needs to be moved from his usual place. For example, if he is a Mechanical Engineer in mechanical maintenance, then he can be put in Production, or vice-versa. If he is a Metallurgical or Electrical engineer, then he can be assigned to the Material Procurement or Training/Safety/Quality sections.
Another usual place (though personally I do not approve of this), in case of outside department transfer, is to put such persons in the Training, O&M, SQC, or Materials department, or even in Township services, even if he is not transferred out-stations or to other sister plants. The idea is to remove the rotten apple from the lot.
Performance and Disciplinary Measures
It might be a good idea to look into his last three Appraisal Ratings and take action based on performance issues, which already include job rotation and transfers. Also, one needs to enlist the support of the Officers' Association too, and somehow bring the matter of his relationship with the Union.
There are several ways and approaches to handle such a situation, with every subsequent step leading towards a progressive disciplinary approach. Finally, his actions can be put under surveillance, and any delinquent behavior dealt with promptly by issuing Warning Letters to start with and then increasing in severity. For this purpose, one can start with punctuality and attendance and then his job performance.
In general discipline management, there is no one-shot tried and tested formula, but several approaches and alternatives that can be used depending on the person and situation. Sometimes, just a mere counseling from HOD and the Personnel Dept. may work.
Do feel free to revert back in case of any clarification or further discussion on the matter.
Warm regards.