Job
Description
Overview To ensure that all processes related to Inventory Management and Store Operation are carried out smoothly at the Plant to consistently provide finished product that meets the business need (product availability, cost & quality) with applicable statutory requirements. To drive operational excellence processes in RMPM Store (M&W/TPM/QMS/EMS) for continual improvement to move operations standards towards world class performance. Assisting HOD manufacturing in delivering productivity & driving a high-performance culture at shop floor. Driving operatives’ engagement on the shop floor includes performance benchmark and appraisals. Managing a team of 65 workmen including contractual worker Large span for managing RM PM inventory and warehouse operation. Driving people engagement & performance driven culture for making this plant one of the best-in-class plants in the PepsiCo global. Responsibilities OPERATIONAL EXCELLENCE: Receiving raw material in the plant and ensuring that it is stocked systematically and safely in the RM Stores Receiving raw material (under inspection) and securing quality clearance for the receipts Deciding the quantity of raw material to be received at a single point of time keeping in mind the capacity in the store (for critical items that are purchased locally) Verifying the bill of the material against the purchase order on Fourth Shift Verifying other documents like excise papers, DRV in the Fourth Shift, IGP register entry, weighing slip Sending sample material promptly to the quality department for quality clearance within 48 hours of receiving the material Receiving Quality Control Report (QCR) from the quality department Monitoring the unloading of the raw material upon receiving satisfactory QCR Unloading packing films for different SKUs separately Stacking this film in separate lots and allotting them different tags Conducting tests for quantity of material wherever required Weighing the filled and empty tanker for checking the quantity of edible oil Conducting dip test and measuring weight of diesel tankers Weighing trucks carrying packing films Weighing raw material for non-PC line: rice meal, corn meal, gram meal, wheat fibre, gram flour etc. Updating stock levels in Fourth Shift, entering new data codes whenever a new raw material for which there is no previous record is received Laying down standards in consultation with the production head and logistics department (HO) for minimum and maximum quantity of raw material to be stored at any point of time, minimum order quantities Obtaining transfer slip and making MORV for receiving ready seasoning drums from the seasoning section Ensuring that the raw materials are stored as per safety precautions to avoid loss during storage Sending alerts to the Plant GM and the HO in case of impending shortages of raw material Issuing of raw material to production whenever required Deciding the quantity of packing film to be issued for the SKUs scheduled to be produced according to the production plan obtained as per schedule Issuing issue slips for the required quantity of raw material that has been certified OK by the quality department Obtaining signed issue slips Ensuring that a nights issue register is filled whenever there are any issues of raw material at night Updating stock levels in the Fourth Shift and the PRRS Ensuring that the materials issue follows the FIFO system Ensuring no downtime due to lack of RMPM Maintaining hygiene and orderliness in the store Designing the stores layout and allocating space for various materials depending on the trends in their consumption and therefore their storage quantity Supervising the stocking of materials according to a systematic layout Stocking the material in FIFO (First In First Out) arrangement Ensuring that the raw material is stored in appropriate physical conditions like lighting, dryness Coordinating with the quality department to conduct regular pest control and cleaning of the store Ensuring that the status of every pallet in the store (Quality OK and not OK) is indicated properly to avoid rechecks at the time of issuing the material Coordinating periodic physical inspection of the store Conducting physical verification at the end of the week for stock issues and returns during the week (unused material and rejected material) Generating weekly efficiency reports for the HO Carrying out a monthly closing of stocks through a physical verification of stores Coordinating quarterly physical inspection by external team Providing stock statements and other information required by the team to conduct the inspection Providing explanation in case there is a discrepancy in the report given by the stores and the report prepared by the external team Maintaining comprehensive and up-to-date records of raw material in MIS Updating stock levels in Fourth Shift at the time of receipt and issue of raw materials Entering new data codes whenever new raw material for which there is no previous record is received Updating the Fourth Shift with entries in the nights issue register Ensuring that NRGPs and STNs (stock transfer notes) are filled every time material is dispatched Freezing all the entries in the BOMs in PRRS, everyday before 3:00 PM for the A-Shift and the next day for B & C Shifts Generating daily stock statements and sending them to the Head Office Preparing and submitting the following reports periodically Weekly closing stock statement from PRRS Monthly closing stock statement Monthly online rejection reports Weekly and monthly film wastage and scrap sale report Monthly report for seasoning flavours Ensuring compliance of records with excise regulations (for 7-8 excisable items) Preparing and submitting RG 23-C Part I (for the status of receipts and issue details of excisable goods) to the despatch department every month Preparing and submitting RG 23-C Part II (for value of modvat claimed on various spare parts) to the accounts department every month Completing Annexure (Clause 57, F-4) for cartons Providing information to the dispatch section in case of show cause notices Providing information to the officials in case of sudden excise checks in the store Claiming modvat credits for items in a timely manner Ensuring proper disposal of scrap and rejected material Collecting rejected material after every week Getting the status of the material from Quality Department Reprocessing documents for disposal of rejected material like 57F form, invoice Supervising the unloading of trolleys carrying the waste material - carton scrap, chip scrap, crushed chips, Weighing the filled trolley and the empty trolley to measure the weight of the scrap Making NRGPs for material that has been rejected Coordinating with the security for disposal of the scrap at the rate that is decided by the Financial Controller Preparing records of waste material by weight and providing to the commercial department BUILDING ORGANIZATIONAL AND SELF CAPABILITY Learning continuously and upgrading own abilities Seeking feedback from team members and seniors Reflecting on own competencies and possible gaps Setting learning goals Monitoring implementation of these goals Continuously updating knowledge from external environment Implementing change initiatives and continuous improvement in own department and plant Identifying areas of improvement and highlighting these to Finance Controller Implementing the action plans developed by the Finance Controller for continuous change Practicing and communicating forward a quality and hygiene focused culture in the plant Generating quality awareness and commitment amongst peers and suppliers Striving to attain continuous improvement of quality audit scores People Management: Preparing multiskilling & detailed deployment plan of operatives through shift scheduling to drive operational discipline, cost & people capability. Driving the targets of Direct Labour cost & TPP, developing backups on redeployment matrix to impact on manpower productivity. Regular coordination with HR team on tracking unauthorized absenteeism and OT trend and ensuring effective communication to sustain good discipline. Production Deliverables: Ensuring compliance to weekly/ monthly production targets as per PepsiCo quality and hygiene standards, delivering SA over & above plan. Maximizing TE/ NE, ensuring conversion efficiencies better than AOP and executing ideas on productivity - sharing views with sector SMEs for troubleshooting and capturing better productivity ideas implemented across other plants as a part of continuous improvement. Coordinating & planning with cross functional team members to ensure seamless production. Capacity Utilization: Maximizing NE/TE by effectively managing and making RMPM available for production utilizing manpower planning in line with actual plan a capacity. Waste Management: Ensuring minimal wastage, optimum manpower utilization and operating at maximum efficiencies. Driving for “ZERO Loss” mantra for the lines with the help of sector team and by utilizing TPM tools & ensuring cross functional involvement (focusing on JH culture on shop floor). Planning and Reporting: Ensuring integrity of data entry across lines, monitoring the data on shift-to-shift basis and reporting of the all the numbers on daily basis in DW as per MNW guidance. IR management: Ensuring line discipline during production - OT, Absenteeism control, motivating the teams for the positive environment at the shop floor. Conducting 1-1 with the operatives, implementation of “Each one teach one” etc on the shop floor for the better engagement and building inclusive culture & keeping the operation disruption free. Key Control: Ensuring KCs of Store operation are maintained in letter & spirit. AIB: Ensuring compliance to food safety as per AIB guidance. Support to Cross function : Enabling effective coordination with support functions & implementation of quality, hygiene, safety & TPM culture that promotes company growth. Cross functional coordination with Agro, LD & T, quality, Engineering, HR & Finance to smoothly run day to day production. Ensuring the “Why-Why Analysis” of b/d on timely manner & implement actions; practice JH to reduce breakdown. Ensure control on consumable cost. SAP management: Batch closing and stock verification in Day store, taking care of GCS, Corporate audit and KC compliances. Ensuring inventory management by proper transferring of FG and taking RM by proper hand shaking between the cross functional departments. NPD handling: Ensuring compliance to all NPD production, reference and Gold sample production in a timely manner with AOP efficiency numbers. Ensuring proper feedback to R&D to build upon the current standards. Cost Management: controlling the optimum consumption of RMPM and developing new vendors for the. M&W & Other audit: Acting as a control owner/ representative of MNW data; quality & safety audit. Qualifications Graduate with 8-10 years of experience of Material Management in large scale operation in FMCG Team player & ability to handle large pool of workmen Excellent communication, both written and verbal Negotiation skills & influencing ability Interpersonal & coordination skills Strong analytical skills Strong focus on delivery and results with high drive and energy level
