Production Manager

Position: Production Manager
Department: Production
Industry: Plywood
Location: Rajkot
Experience: 815 years in plywood manufacturing
Qualification: Diploma / B.E. / B.Tech in Mechanical, Production, Industrial Engineering, or related discipline

Job Purpose

To lead and manage the complete production operations of the plywood manufacturing plant, ensuring achievement of production targets, product quality, optimum utilization of manpower and machinery, cost efficiency, minimum wastage, and adherence to safety and operational standards.

Key Responsibilities

1. Production Planning & Execution

• Plan and execute daily, weekly, and monthly production as per business requirements.
• Ensure production targets are achieved within defined quality, cost, and delivery parameters.
• Monitor production processes from log preparation, peeling/veneer production, drying, grading, glue preparation, core/face assembly, pressing, trimming, sanding, finishing, and packing.
• Optimize production schedules based on machine capacity, manpower availability, raw material availability, and dispatch requirements.
• Identify and eliminate production bottlenecks and improve overall plant throughput.

2. Productivity & Cost Control

• Monitor key production parameters such as output, yield, cycle time, machine utilization, rejection, and wastage.
• Drive initiatives for improvement in production yield and reduction of material and process losses.
• Control consumption of timber, veneer, resin/glue, chemicals, fuel, electricity, and other production inputs.
• Implement Lean Manufacturing / Kaizen / 5S practices wherever applicable.
• Analyse production MIS and take corrective actions for deviations.

3. Manpower Management

• Plan manpower requirements according to production volume and shift schedules.
• Supervise production officers, supervisors, operators, and contract workforce.
• Allocate manpower effectively across production lines and shifts.
• Develop employee capability through on-the-job training and skill enhancement.
• Maintain discipline and ensure adherence to company policies and shop-floor procedures.

4. Quality Management

• Ensure adherence to defined quality standards and product specifications.
• Coordinate with the Quality Assurance/Quality Control team to minimize defects and customer complaints.
• Identify root causes of quality issues and implement CAPA.
• Ensure proper process control at every critical stage of manufacturing.
• Maintain consistency in product quality, thickness, bonding strength, appearance, moisture, and finishing.

5. Machine & Equipment Utilization

• Ensure optimum utilization and availability of production machinery.
• Coordinate with the Maintenance Department for preventive and breakdown maintenance.
• Monitor recurring machine breakdowns and support root-cause analysis.
• Suggest process and equipment modifications to improve productivity and efficiency.
• Ensure proper machine operating procedures are followed.

6. Raw Material & Inventory Coordination

• Coordinate with Procurement and Stores for timely availability of timber, veneer, chemicals, adhesives, and other production materials.
• Monitor raw material quality and suitability for production.
• Ensure proper storage and handling of production materials.
• Control production-related inventory and avoid unnecessary material accumulation.

7. Safety & Compliance

• Ensure strict compliance with plant safety rules and statutory requirements.
• Conduct regular safety checks and promote a strong safety culture on the shop floor.
• Ensure use of appropriate PPE by all employees.
• Investigate production-related incidents and implement preventive measures.
• Maintain housekeeping and 5S standards across the production area.

8. MIS & Reporting

• Prepare and review daily, weekly, and monthly production reports.

• Track production achievement against targets and analyse variances.

• Monitor KPIs including:

• Production Output

• Yield %

• Machine Utilization

• Rejection %

• Wastage %

• Production Cost

• Downtime

• Labour Productivity

• Energy Consumption

• Present production performance and improvement plans to Plant Head / Management.

9. Cross-Functional Coordination

• Coordinate with Quality, Maintenance, Stores, Procurement, PPC, Dispatch, EHS, and HR for smooth plant operations.
• Work closely with PPC/Planning to align production with customer and dispatch requirements.
• Coordinate with the Quality team to resolve process and product-quality issues.
• Support management in implementing new products, processes, and productivity initiatives.

Key Competencies

• Strong knowledge of plywood manufacturing processes.
• Production planning and shop-floor management.
• Strong manpower handling and leadership skills.
• Knowledge of veneer, plywood pressing, glue/resin, sanding, trimming, and finishing processes.
• Knowledge of production KPIs and manufacturing MIS.
• Problem-solving and root-cause analysis.
• Cost and wastage control.
• Quality-conscious approach.
• Strong communication and coordination skills.
• Ability to work in a target-driven manufacturing environment.
• Knowledge of 5S, Kaizen, Lean Manufacturing, and continuous improvement practices.