Production Shift In-Charge

Wafer & Chocolate Plant

Department: Production

Reports To: Production Manager / Plant Head

Shift: Rotational Shift

1. Job Purpose

To independently manage and control production activities during the assigned shift, ensuring safe, efficient, and continuous production of wafer and chocolate products while achieving production targets, quality standards, minimum wastage, and optimum manpower and machine utilization.

2. Key Responsibilities

Production Operations

• Plan and execute daily production as per the production schedule.
• Operate and monitor wafer ovens, wafer sheet lines, cream preparation, cutting, stacking, chocolate melting, tempering, enrobing, cooling tunnels and related equipment.
• Ensure production targets are achieved within the planned time.
• Monitor machine speed, production output, downtime and line efficiency.
• Maintain continuous production and take immediate corrective action during breakdowns or process deviations.
• Ensure proper start-up, changeover and shutdown procedures.

Process Control

• Monitor critical process parameters such as:
  • Wafer sheet thickness, weight and moisture
  • Cream quantity and application
  • Wafer dimensions and stacking
  • Chocolate temperature and viscosity
  • Tempering parameters
  • Enrobing/chocolate coverage
  • Cooling tunnel temperature and conveyor speed
  • Product weight and dimensions
• Ensure products are manufactured according to approved specifications and SOPs.
• Coordinate with QA/QC for product inspection and approval.

Manpower Management

• Allocate operators and helpers according to production requirements.
• Control manpower attendance, discipline and productivity.
• Train operators on machine operation, SOPs, GMP and safety requirements.
• Monitor operator performance and ensure proper work practices.

Machine & Maintenance Coordination

• Closely coordinate with Mechanical, Electrical and Automation Maintenance teams for breakdowns.
• Report abnormal machine conditions immediately.
• Follow up on breakdowns until the machine is restored.
• Monitor recurring breakdowns and communicate major issues to the Production Manager.
• Ensure proper cleaning and basic operator-level maintenance of equipment.

Material Management

• Ensure availability of raw materials and packaging materials before starting production.
• Coordinate with Stores and Planning for timely material supply.
• Control material consumption and minimize production losses.
• Monitor chocolate, wafer, cream and packaging material wastage.

Quality & Food Safety

• Ensure compliance with GMP, HACCP, food safety and hygiene requirements.
• Maintain personal and production-area hygiene.
• Prevent cross-contamination and foreign-material risks.
• Ensure rejected/non-conforming products are properly identified and segregated.
• Maintain traceability and batch records.

Wastage & Efficiency Control

• Monitor daily production wastage and identify the major causes.
• Take corrective actions to reduce:
  • Wafer breakage
  • Chocolate losses
  • Start-up/changeover losses
  • Cutting losses
  • Packing rejection
  • Overweight/underweight products
• Improve OEE, line efficiency and production yield.

3. Shift Documentation & Reporting

The Shift In-Charge shall maintain and submit:

• Shift production report
• Machine running hours and downtime report
• Production achievement vs. target
• Wastage report
• Manpower deployment
• Material consumption report
• Quality/rejection report
• Breakdown report
• Changeover report
• Cleaning and sanitation checklist
• Shift handover report

4. Coordination With Other Departments

The Production Shift In-Charge will coordinate closely with:

• QA/QC – Quality and food safety
• Mechanical Maintenance – Mechanical breakdowns
• Electrical/Automation – Electrical and control issues
• Engineering/Projects – Machine modifications and improvements
• Stores – Raw materials and spares
• Planning – Production schedule
• Packing – Product transfer and packing availability
• Utility/Kitchen – Chocolate, cream, water, chilled water and other utilities

5. Safety Responsibilities

• Ensure all operators follow plant safety procedures.
• Stop unsafe operations immediately.