Food Production Factory Manager
ALIMENTO AGRO FOODS PVT LTD
Total years of experience :18 years, 7 Months
JOB DESCRIPTION:
Looking after the over all supply chain operations from raw material procurement to dispatch in which providing an oversight and direction to all operational functions, including raw & packaging material planning & procurement, manufacturing processes, procurement, quality, logistics, stores, ware house/inventory management interms of raw/packaging/engg & finished goods, maintenance, projects, safety, HR etc.
Have a key leadership role in leading the operations & the people management in the facility. This role is reporting to the Management / Top Management with daily coordination .Formed the part of the senior operational team, and manage the operation strategically.
Overall, responsible for the smooth flow of high-quality product, delivered efficiently within a set budget. Vital to business success, the packing operation functions and distribution, requires constant monitoring for cost effectively, reducing waste and maximizing profitability.
As a key member of the management team it is solely responsible & collaborate closely with cross function teams & company’s seniors to shape the strategic direction of the company and ensure its seamless functioning.
Also, involved in developing new Ideas for better profitability, improving procurement methods and exploring new business opportunities. Strong and decisive operations leader with excellent analytical, organisational, Team building and planning skills. Maintain uncompromising focus on high quality standards and bottom-Line profit improvement, effective technical and communication abilities.
Roles & Responsibilities
Provide leadership to all the aspects of the manufacturing operations.
Facilitate, coach, council & guide the manufacturing team to ensure they can deliver results.
Educate, develop and motivate the manufacturing team to achieve required production results.
Develop & implement operating policies & procedures to achieve stated goals.
Strive for continuous improvement in manufacturing processes to ensure efficiencies & eliminate waste and implement such plans through prople, processes, procedures & equipments.
Exercies direct supervision over R & D department, general supervisors and line supervisors concerning production volume, cost and quality of production to meet production schedules & delivery dates.
Meet the financial objecties and goals by forecasting requirements and supporting the annual budget process.Experience in the departmentwise budgeting for the whole year.
Review production costs and product quality and modify production and inventory control programs to maintain and enhance the profitable operation of the plant.
Direct and lead all operations to achieve monthly profit results with a focus on operations throughout.
Good knowledge of production management, quality standards & safety measures..
Having good experience in evaluating the performance matrix & providing necessary resources to increase the skill level of the individual .
Having a vast experience in procuremnent, negotitating &, developing local vendors for buying equipments.
GRINDING & PACKAGING PRODUCTION FUNCTION :
In the blending section there is a single cryogenic pneumatic conveying line for grinding & blending whole spices into powder.The lines are from axtel processing system, Vadodara.
Having an excellent knowledge of spices grinding & it’s related equipments like pulvarisers, automatic grinding lines with cryogenic facility .
To monitor the shift activities as per quality compliance.
To achieve the production targets as per schedule. Ensure that product manufactured are free from any kind of quality defects.
Having machines like Vertical Form Filling & Sealing (VFFS) of PAKONA, XPERT & Jar packaging machine in the packaging department & having an excellent knowledge of them.
Having a good knowledge of primry & secondary packaging .
Easily handling the large manpower team & directing production incharge to make their shift schedule.
Proper utilisation of manpower for eliminating breakdowns on parallel machines or in the shift
Implementing the kaizen and new ideas by brain storming for the product cost reduction.
co-ordination with various departments for processing purpose & for impleamenting new ideas.
Keep an eye on the cost of production consumbales & over all costing of the departments
keep a close track of machine wise inventory and spare parts management with a monthly audit .
Having an excellent knowledge of different losses related to machines which effects it’s productivity and how to minimise it.
Keep a close watch on the machine wise MTBF ( Mean Time Between Failures ) & MTTR (Mean Time To Repair ) & OEE.
Other Responsibilities :
Develop and implement Operation manual, Procedures, HACCP, and Operational control procedures.
Manage capacity (hours, people, and equipment) to efficiently meet the demand.
Make sure for visit the Unit on a regular basis to monitor and audit production.
Create, implement and Audit whether units are following the production SOPs.
Assess and make sure the units are equipped with right kind of production & dispatch equipment, facilities, machineries and staff.
Ensure continuous availability of senior resources of the unit by effectively managing them and continuously in touch with the HO, Ahmedabad.
Identify production difficulties and deal with any problems or delays as they arise. Train the workers, new joinees and HOD’s to handle the situation for future
Train the new employee on the production, Quality, Safety and Hygiene processes.
Troubleshoot production, machinery or Labour problems and take corrective actions to ensure continuity of production.
Create maintenance standards for the unit and audit whether the same is being implemented and records are kept.
Implented various techniques like JH step 0, JH step 1, know your machine and its’ spare parts for spreading the awareness about the machine and it’s maintenance among the different team of workers who are not aware about them.
Implementing kaizens from different departments, cost saving small projects and present those to HO by presentation.
Actively participating in the yearly FSSC 22000 audit . Review all the procedures, SOPS, legal documents, procedures, systems & records .Review QA standards set for the production, for Raw Materials, and finished goods and make sure they are implemented in total and records are kept. Continually assess existing processes and strive for process improvement in order to create efficiencies in processes and workflows by putting extra checks of quality department. Also, ready meal sample kept for atleast 72 hours for tracability incase of any complaint from the schools related to particular day food quality.
ROLES & RESPONSIBILITIES AT EVEREST SPICES PVT LTD, GUJARAT.:
BLENDING / PROCESSING DEPARTMENT FUNCTION :
Worked as a Production/Process Executive in EVEREST SPICES PVT LTD. Heading Overall responsibilities for all activities pertaining to processing & blending operations.
RESPONSIBILITIES :
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• In the blending section there are 3 long pneumatic conveying lines for grinding & blending whole spices into powder.The lines are from axtel processing system, vadodara
• To monitor the shift activities as per quality compliance.
• Take part in the monthly production planning forecasting team for the monthly & yearly production target as per the market demand
• Designing & setting up production facility in the plant.
• Interaction with production planning team and also customers to understand the market demand.
• Machine wise making a weekly & monthly production plan and it's adherence.
• To achieve the production targets as per schedule. Ensure that product manufactured are free from defects.
• Well conversant with GMP, Hygine, HACCP, FSSAI, and FSSC 22000 standard.
• To assume responsibility of improving efficiency and quality of overall production of packaging & blending operations.
• Handling the overall manpower in packaging & blending sections which includes company employees & contractual workers, also making their shift schedules & also do new recruitments.
• To ensure safe operation in blending section& packaging section by impleamenting work permit system for different kinds of work.
• Timely reporting of Safety, Quality, Food Safety, Equipment Down Time, People related incidents.
• Ensuring 5 S in across packaging and blending area.
• To ensure Operator Standard Work in all blending operations.
• To analyze Root Cause and executing CAPA for all failures in blending & packaging section.
• To ensure batch records and other documents are maintained as per SOP.
• Regular checking of the documenation filling compliance.
• To engage self and blending team on continuous improvement of overall operations.
• Take responsibility for the career development /planning and performance discussion of the team members by continuous training / coaching of shift crew in the span of control.
• Manage line or production scheduling and plan work force utilization to ensure efficient use of the company resources and timely delivery to customer.
• Train the workers and colleagues for systematic working in terms of TPM . Encouraging the workers for KAIZENS by giving prizes.
• Thorughly given training to workers and staff for machine technical issues and make them prepare for autonomous maintnenance.
• Ensuring for all the Statutory compliances under Factories Act, Other applicable acts & rules.
• Impleamenting the 5S, one point lesson, RCA & tools like CAPA in the department.
• Handling the overall manpower in the deparment and make their shift schedule.
• Proper utilisation of manpower for eliminating breakdowns on parallel machines or in the shift
• Analysis of different techniques such as one pointlesson, root cause analysis and why-why analysis.
• Worked hand to hand with the project team for implementation of new projects from the installation level to the production handover.
• Reduction of overall instrumentation, electrical & mechanical related downtime for better productivity.
• Implementing the kaizen and new ideas by brain storming for the product cost reduction.
• co-ordination with other departments for processing purpose.
• Keep an eye on the cost of production consumbales & over all reduced costing of the departments
• Having an excellent knowledge of Mitsubishi plc, ladder logic, wiring and different electrical, instrumentation related equipments inside the machine and also of machine electrical drawing.
• keep a close track of machine wise inventory and spare parts management .maintaing the machine wise MTBF (Mean Time Between Failures ), MTTR (Mean Time To Repair ) & OEE.
ROLES & RESPONSIBILITES AT HINDUSTAN UNILEVER LIMITED :
Worked in the plant of kissan jam and tomato ketchup line in silvasa factory and having an expertise in the
Bottling line Products. Streamlined various measures to enhance operational efficiency and working
As a Manufacturing executive.
PACKAGING PRODUCTION FUNCTION :
• Worked as a shift inchrge so achieve the shift production targets as per schedule. Ensure that product manufactured are free from defects.
• Also handling the Vertical Form Filling & Sealing machine (VFSS) of Hassia in the powder plant with augar arrangement.
• To monitor the shift activities as per quality compliance.
• Impleamenting the 5S, one point lesson, RCA & tools like CAPA in the department for any customer complaint if there.
• Handling the overall manpower in the deparment and make their shift schedule.
• Randlomly checking for over all documentation filling adherence.
• Handling the IQA (Intenal Quality Audit) held by quality dept quarterly.
• Having an excellent knowledge of relay & contactor base logic of control panels and programming in PLC with solution of the problems related to same by thoroughly checking of programme(ladder logic) and electrical drawing.(loop testing mathod).
• Modification of automation related requirements inclusive of the PLC ladder logic development and electrical controls troubleshooting
• Regular calibration of Pressure, Level & flow transmitters, mass flow meters, different kinds of valves (gate valves, butterfly valves, control valves ), different kinds of sensors and hands on experience in the programming on Allen Bradley PLC like Micro Logix 1000, 1200, 1500, compact logic, control logic & SLC series, knowledge of servo drives, variable frequency ac drives with temperature controllers and also Having a very detailed knowledge of butter-fly valves, ball valves and control valves.
• New installation of projects and automation of machines
• Up-dation of all machines backup and made the inventory of all machines
• Maintain the records in terms of history card for each and every quipement with PM sheet.
• Regulaly Maintaing the log book for the daily shift wise breakdown and generating the red tags and white tags accordingly.
• Exploring a very good knowledge of hookup diagram, instrumentation data sheet and electrical drawing.
• Finalising the yearly budget for stock or catelogue items(frequently used and imp spares) and nonstock items(directly buying by generating purchase order).Also finalising capex for the year for costly equipements at the initial phase of every year.
• As per the weekly and monthly production plan, PM schedule is made and followed rigourously.
• Maintaing the spares with ROL(RE ORDER LEVEL) and ROQ(RE ORDER QTY) for the catelogue or the stock items.
• Vendor development, negotiation with the vendors for comparative lowest rate in the market, Taking the comparative qutoes from 2 to 3 differents vendors for the same item, raise the Purchase Orders in portal, make that approved, send that to vendor and finally clearing their invoices.
• Take care of condtional (predictive) based maintenance to predict the actual service life of the part or the equipment by LLF(look, listen & feel) and CLIT for each and every day to plan the Preventive Maintenance schedule.
Done the project on damaged bottle detection using the software VC++