Senior Manager - Operations (Corp. Manufacturing)

Job Objective

• Collaborate with head of Manufacturing to develop and implement strategic plans aimed at optimizing productivity and operational efficiency.
• Uphold the highest standards of excellence and quality throughout all manufacturing processes, ensuring products meet or exceed customer expectations.
• Ensure adherence to all necessary statutory and regulatory compliance requirements relevant to manufacturing operations.
• Be accountable for achieving production targets as outlined in the Annual Operating Plan (AOP), ensuring alignment with overall business objectives.
• Optimize the utilization of plant machinery and resources to achieve set production goals while minimizing waste and downtime.
• Maximize spare capacity utilization by engaging Contract Manufacturing Units (CMUs) for co-packaging and other operational needs as required.
• Ensure strict adherence to the approved budget for running plant operations, implementing cost-control measures while maintaining quality standards.
• Lead digitalization initiatives and SAP process development to ensure a smooth flow of value streams across manufacturing operations, enhancing data integration and operational agility.

Primary responsibilities

1)

Collaborate with Leadership:

Work closely with the Manufacturing Head to develop and refine the overall manufacturing strategy, ensuring alignment with organizational goals and market demands.

Develop Strategic Plans:

Formulate strategic plans aimed at optimizing productivity across all manufacturing processes, identifying opportunities for efficiency gains and cost reductions.

Enhance Plant Effectiveness:

Review and improve plant effectiveness by developing robust processes, overseeing employee GCL-Corp HR/Plant Head SFD-JD-KRA-KPI-2022-23 – 01 performance, and establishing a highly motivated work environment that encourages innovation and continuous improvement.

Monitor Performance Metrics:

Establish and monitor key performance indicators (KPIs) to assess operational efficiency and effectiveness, making data-driven decisions to enhance productivity.

Resource Allocation:

Optimize resource allocation across manufacturing operations to ensure that personnel, equipment, and materials are utilized effectively in line with strategic objectives.

Risk Management:

Identify potential risks in manufacturing processes and develop mitigation strategies to ensure operational continuity and compliance with industry regulations.

Foster Cross-Department Collaboration:

Collaborate with various departments to align operational strategies with business objectives, ensuring seamless communication and coordination across functions.

Functional

A)

Production Planning and Execution

a) Prepare monthly production plans and indents based on sales forecasts and operational capabilities.

b) Assess requirements for raw materials and packaging materials to ensure uninterrupted production flow.

c) Develop production plans as per sales indents to optimize resource utilization and meet customer demand.

d) Monitor day-wise production activities to ensure compliance with production indents and operational standards.

e) Ensure production plan compliance while adjusting operations based on feedback and market demands.

Operational Oversight

a) Oversee day-to-day operations, assigning weekly performance goals to team members and ensuring their completion while achieving personal objectives.

b) Maintain project timelines to ensure all tasks are accomplished on schedule, facilitating timely delivery of products.

c) Monitor packaging and process line efficiency to achieve set targets while maintaining quality standards.

d) Ensure hygiene and housekeeping standards are maintained in the production area to comply with safety regulations.

Performance Monitoring

a) Cascade overall operations plan to reporting teams by setting daily, monthly, and quarterly targets to facilitate execution and regular monitoring.

b) Monitor business unit performance parameters such as lead time, capacity utilization, quality metrics, etc., taking corrective action for course correction in case of deviations from targets.

c) Generate and maintain Management Information System (MIS) reports, including production reports, raw material and packing material consumption reports, tracking material efficiencies, and Overall Equipment Effectiveness (OEE) on a daily and monthly basis.

Supply Chain Management

a) Oversee supply chain operations, ensuring finished goods are delivered on time with accurate invoicing.

b) Maximize spare capacity utilization by engaging Contract Manufacturing Units (CMUs) for co-packaging and other operational needs as required.

c) Plan for CMU yields to ensure alignment with production goals.

Cost Optimization

a) Develop, implement, and maintain budgetary plans and resource allocation strategies to optimize operational efficiency.

b) Analyse raw material, packing material, and manpower yields to identify areas for cost savings and efficiency improvements.

c) Manage labour utilization effectively, implementing cost-saving initiatives while maintaining productivity levels.

Process Improvement

a) Provide expertise in manufacturing process optimization, including assembly line design, quality checks, process design, inventory management, etc.

b) Contribute to the development and drive implementation of operational excellence initiatives and standardization across the manufacturing unit.

Problem Resolution

a) Propose action plans to resolve high-level escalations or problems raised by business units, monitoring adherence by the concerned departments.

B)

Establish Quality Control Standards:

a) Develop and implement quality control processes that align with industry standards to ensure consistent, high-quality production output.

Monitor Production Quality:

a) Oversee the manufacturing process to ensure that products are produced according to established quality specifications, conducting regular inspections and audits.

Implement Continuous Improvement Initiatives:

a) Identify areas for process improvement and implement strategies that enhance product quality, reduce defects, and optimize production efficiency.

Conduct Root Cause Analysis:

a) Analyse quality issues and defects to determine root causes, developing corrective action plans to prevent recurrence and improve overall product quality.

Stay Updated on Industry Standards:

a) Keep abreast of changes in industry regulations and standards related to quality control, ensuring compliance and adapting processes as necessary.

Foster a Culture of Quality:

a) Promote a culture of quality within the organization by encouraging employee involvement in quality initiatives and recognizing contributions to quality improvement efforts.

C)

Support to NPD Train Staff on New Procedures:

a) Provide training to production staff on new product specifications, handling procedures, and quality control measures to ensure smooth transitions and adherence to standards.

Monitor Initial Production Runs:

a) Oversee the first runs of new products on the manufacturing line, closely monitoring performance metrics such as yield rates, defect rates, and overall equipment effectiveness (OEE).

Conduct Root Cause Analysis for Defects:

a) Analyse any quality issues or defects that arise during initial production runs of new products, developing corrective action plans to address root causes.

Implement Continuous Improvement Initiatives:

a) Identify opportunities for process improvements based on feedback from initial production runs of new products, optimizing workflows to enhance efficiency and product quality.

Coordinate Cross-Functional Collaboration:

a) Facilitate communication between manufacturing, R&D, and marketing teams to ensure that all aspects of new product launches are aligned and executed smoothly.

Utilize Key Performance Indicators (KPIs):

a) Track and analyse KPIs related to new product performance, including production efficiency, quality metrics, and customer feedback, to drive ongoing improvements.

Foster a Culture of Innovation:

a) Encourage a culture that embraces innovation and continuous improvement within the manufacturing team by recognizing contributions to successful new product launches.

D)

Optimize Flow of Materials:

a) Ensure efficient flow of materials through the manufacturing process by coordinating with procurement, production, and logistics teams to maintain optimal inventory levels.

Monitor Cost Management:

a) Track and analyse costs associated with materials and production processes within SAP, identifying areas for cost reduction and efficiency improvements.

Ensure Data Accuracy:

a) Maintain accurate data entry in the SAP system related to inventory levels, production schedules, and material usage to facilitate effective decision-making.

Conduct Training on SAP Usage:

a) Provide training to staff on SAP functionalities related to materials management and cost tracking, ensuring that all team members are proficient in using the system effectively.

Implement Continuous Improvement Initiatives:

a) Identify opportunities for process improvements within the SAP framework that enhance material flow efficiency and reduce waste.

Collaborate with Cross-Functional Teams:

a) Work closely with finance, procurement, and production teams to ensure alignment of material flow strategies with overall business objectives and financial goals.

Analyse Key Performance Indicators (KPIs):

a) Track KPIs related to material flow, inventory turnover, and cost efficiency, providing regular reports to senior management on performance metrics.

Ensure Compliance with Standards:

a) Ensure that all processes related to material handling and cost management comply with industry standards and internal policies.

Data Collection and Management:

a) Oversee the collection, input, and distribution of operational data within the organization’s systems, ensuring data accuracy and integrity.

Analyse Complex Data Sets:

a) Utilize statistical techniques to analyse complex data sets, extracting meaningful insights that support decision-making and operational improvements.

Develop Reporting Frameworks:

a) Create and implement reporting frameworks that provide stakeholders with clear visibility into operational performance metrics, trends, and areas for improvement.

Monitor Key Performance Indicators (KPIs):

a) Track and analyse KPIs related to operational efficiency, quality, and cost-effectiveness, providing regular updates to senior management.

Collaborate with Cross-Functional Teams:

a) Work closely with other departments to identify data needs and reporting requirements, ensuring alignment with organizational goals.

Implement Continuous Improvement Initiatives:

a) Identify opportunities for process enhancements based on data analysis findings, implementing strategies that drive operational excellence.

Train Staff on Data Tools:

a) Provide training and support to employees on data analysis tools and best practices, fostering a culture of data-driven decision-making.

Ensure Compliance with Data Governance:

a) Maintain compliance with data governance policies and best practices, ensuring that all data handling processes meet regulatory requirements.

Present Findings to Stakeholders:

a) Prepare and present reports and visualizations to communicate findings and recommendations to senior management and other stakeholders effectively.

Stay Updated on Industry Trends:

a) Keep abreast of industry trends in data analytics and operations management, integrating new techniques and technologies into existing processes as appropriate.

Any other additional responsibility could be assigned to the role holder from time to time as a standalone project or regular work. The same would be suitably represented in the Primary responsibilities and agreed between the incumbent, reporting officer and HR.