Production Manager

JOB DESCRIPTION

Production Manager Pearlescent Pigment Manufacturing Plant

Company: Pearlescent Minchem (India) Pvt. Ltd.
Department: Production
Position: Production Manager
Reporting To: Plant Head / General Manager / Director
Location: Hosur, Tamil Nadu
Employment Type: Full-Time

1. Job Purpose

The Production Manager will be responsible for the overall planning, execution, supervision, and control of manufacturing operations for pearlescent pigments and related mica-based products.

The candidate will be responsible for achieving production targets while maintaining consistent product quality, optimum chemical and raw-material consumption, minimum wastage, high plant efficiency, safe operations, and controlled manufacturing costs.

The Production Manager will work closely with QC/QA, Maintenance, Stores, Purchase, EHS and Management to ensure smooth and efficient plant operations.

2. Key Responsibilities

A. Production Planning & Execution

• Plan daily, weekly and monthly production according to customer orders and management targets.
• Prepare production schedules based on raw-material availability, plant capacity and delivery requirements.
• Ensure timely execution of production batches from mica preparation through coating, filtration/washing, drying, calcination and final processing/packing, as applicable.
• Monitor production progress against planned targets.
• Ensure optimum utilization of reactors, filters, dryers, calciners, furnaces and other production equipment.
• Identify production bottlenecks and take corrective action.
• Maintain proper batch-wise production records and traceability.

B. Process Control

• Ensure production is carried out strictly according to approved SOPs, batch sheets and process parameters.
• Monitor critical process parameters such as:
• Temperature
• pH
• Reaction time
• Chemical addition rate
• Agitation
• Filtration/washing conditions
• Drying conditions
• Calcination temperature and time
• Material moisture
• Batch yield
• Ensure consistency between batches.
• Work with QC/QA to investigate deviations and implement corrective actions.
• Develop and improve process parameters to increase product quality and production efficiency.

C. Chemical & Raw-Material Consumption

A major responsibility of the Production Manager will be controlling manufacturing cost through efficient consumption of raw materials and chemicals.

• Monitor consumption of TiOCl, Sn compounds, NaOH, HCl and other process chemicals.
• Monitor mica, fuel, LPG/LDO, electricity and other consumables.
• Compare actual consumption against standard/BOM consumption.
• Investigate abnormal chemical consumption and material losses.
• Reduce process wastage and unnecessary chemical usage.
• Prepare monthly chemical consumption and production efficiency reports.
• Work with Management to establish and continuously improve standard consumption norms.

D. Production Yield & Cost Control

• Monitor batch-wise and monthly production yield.
• Analyse input vs. output quantity.
• Identify reasons for yield losses.
• Reduce rejection, rework and process losses.
• Monitor manufacturing cost per kg.
• Identify opportunities for reduction in:
• Chemical cost
• Fuel consumption
• Electricity consumption
• Labour cost
• Process losses
• Packing cost
• Downtime
• Suggest practical process improvements to Management.

E. Manpower Management

• Supervise production operators, helpers, technicians and other plant personnel.
• Allocate manpower according to production requirements.
• Prepare shift-wise manpower deployment.
• Ensure discipline, attendance and proper work practices.
• Train operators on process SOPs, equipment operation, safety and quality requirements.
• Develop skilled operators who can independently handle critical processes.
• Evaluate operator performance and identify training requirements.

F. Equipment & Maintenance Coordination

• Ensure production equipment is operated correctly and efficiently.
• Coordinate with the Maintenance Department for preventive and breakdown maintenance.
• Minimize production downtime.
• Immediately report recurring equipment problems to Management/Maintenance.
• Participate in preventive-maintenance planning.
• Ensure reactors, pumps, filters, dryers, calciners, furnaces, agitators and other equipment are maintained in proper operating condition.

G. Quality Coordination

• Work closely with QC/QA to ensure every batch meets approved specifications.
• Ensure production batches are properly identified and traceable.
• Investigate customer complaints and internal quality deviations related to production.
• Implement corrective and preventive actions.
• Ensure rejected/off-spec material is properly identified and segregated.
• Maintain strict adherence to approved process parameters.

H. Safety & Environmental Responsibility

• Ensure all production activities are carried out safely.
• Ensure workers use appropriate PPE.
• Enforce safe handling and storage of acids, alkalis, titanium chemicals and other hazardous materials.
• Ensure safe operation of high-temperature equipment and furnaces/calciners.
• Follow company EHS procedures and statutory requirements.
• Report accidents, near misses and unsafe conditions immediately.
• Ensure good housekeeping and 5S practices throughout the production area.
• Coordinate with EHS/Management regarding effluent, wastewater and chemical waste handling.

I. Documentation & Reporting

Maintain and review:

• Daily Production Report
• Batch Manufacturing Records
• Production Planning Sheet
• Raw Material Consumption Report
• Chemical Consumption Report
• Production Yield Report
• Rejection/Rework Report
• Machine Downtime Report
• Manpower Report
• Energy/Fuel Consumption Report
• Production Cost Report
• Process Deviation Reports
• Corrective Action Reports

Prepare daily, weekly and monthly production MIS for Management.

3. Key Performance Indicators (KPIs)

The Production Manager will be evaluated based on:

1. Achievement of monthly production targets.
2. Production cost per kg.
3. Chemical consumption per kg of finished product.
4. Raw-material yield.
5. Batch rejection percentage.
6. Rework percentage.
7. Machine utilization.
8. Production downtime.
9. LPG/fuel consumption per kg.
10. Electricity consumption per kg.
11. On-time completion of production plans.
12. Product quality consistency.
13. Reduction in process losses.
14. Manpower productivity.
15. Compliance with SOP, safety and quality requirements.

4. Candidate Profile

Education

• B.E./B.Tech./Diploma in Chemical Engineering, Mechanical Engineering, Production Engineering, Industrial Engineering or related field.
• Candidates with relevant manufacturing experience and strong practical knowledge may also be considered.

Experience

Preferred: 510 years of experience in chemical, pigment, coating, specialty chemical, mineral processing or similar manufacturing industries.

Experience in any of the following will be an advantage:

• Pearlescent pigment
• Titanium dioxide / TiO
• Mica processing
• Pigment manufacturing
• Chemical coating
• Wet chemical processing
• Calcination
• Filtration and drying
• Specialty chemicals
• Batch chemical manufacturing

5. Technical Skills Required

The candidate should have practical knowledge of:

• Batch chemical manufacturing
• Chemical reaction processes
• pH and temperature control
• Chemical dosing
• Filtration and washing
• Drying processes
• Calcination/furnace operation
• Material balance
• Yield calculation
• Chemical consumption calculation
• Production planning
• Process optimization
• Equipment utilization
• Preventive maintenance coordination
• Industrial safety
• Excel and production MIS

Knowledge of ERP/MRP or production management software will be an advantage.

6. Desired Personal Qualities

The ideal candidate should be:

• Strong in hands-on plant management
• Technically sound and practical
• Good at troubleshooting
• Data-oriented and analytical
• Cost-conscious
• Disciplined and responsible
• Strong in manpower handling
• Able to work under production pressure
• Proactive in identifying problems
• Good at communication and coordination
• Focused on continuous improvement
• Willing to spend substantial time on the shop floor

This is a hands-on production position and is not limited to office-based production planning.

7. Authority & Decision-Making

The Production Manager will be authorized to:

• Allocate production manpower.
• Plan daily production activities.
• Adjust production schedules according to plant conditions.
• Stop unsafe production activities.
• Escalate quality/process deviations.
• Recommend changes in process parameters after proper evaluation.
• Recommend improvements in equipment, manpower and process methods.
• Recommend disciplinary/training actions for production personnel.

Major changes in formulation, process specifications, raw materials or production cost standards will require Management/QC approval.

8. First 90-Day Expectations

During the first three months, the Production Manager is expected to:

First 30 Days

• Understand all manufacturing processes.
• Study existing SOPs and batch records.
• Understand equipment and plant capacity.
• Understand chemical/raw-material consumption.
• Identify major production problems and bottlenecks.

3160 Days

• Establish reliable production monitoring.
• Improve manpower utilization.
• Start batch-wise consumption and yield analysis.
• Identify major sources of wastage.
• Improve production discipline and documentation.

61–90 Days

• Implement measurable process improvements.
• Reduce abnormal chemical consumption and process losses.
• Improve production efficiency and equipment utilization.
• Establish monthly production and cost KPIs.
• Submit a continuous-improvement plan to Management.

9. Important Note for Recruitment

Priority should be given to candidates who have actually worked inside a chemical manufacturing plant and have hands-on experience in production operations, rather than candidates whose experience is primarily administrative or planning-oriented.

The selected candidate should be capable of personally troubleshooting production problems, analysing chemical consumption, controlling operators, understanding process chemistry and improving plant productivity.

Probation: 3–6 months.

Joining: Immediate / As mutually agreed.

Reporting Location: Hosur, Tamil Nadu.Role & responsibilities