Production Manager

1. Job Purpose

To manage and supervise the complete production operations of wall putty, tile adhesive, and other dry-mix mortar products, ensuring consistent product quality, optimum production efficiency, cost control, timely dispatch, and compliance with safety standards.

2. Key Responsibilities

A. Production Planning and Execution

• Plan daily, weekly, and monthly production according to sales orders and dispatch requirements.
• Manage manufacturing of wall putty, tile adhesives, block jointing mortar, plaster, and other dry-mix products.
• Ensure proper batching, mixing, blending, sieving, and packing operations.
• Monitor production output, machine utilization, downtime, and overall plant efficiency.
• Ensure timely completion of production targets while minimizing wastage and rework.

B. Raw Material and Formulation Management

• Ensure availability and proper utilization of raw materials such as cement, graded silica sand, calcium carbonate, white cement, polymers, cellulose ethers, starch ethers, and other additives.
• Follow approved product formulations, batch sheets, and standard operating procedures (SOPs).
• Maintain accurate batch records, material consumption reports, and production documentation.
• Coordinate with R&D and Quality Control for formulation trials, product improvement, and troubleshooting.
• Minimize formulation deviations and raw material losses.

C. Quality Control

• Coordinate with the Quality Control team to maintain consistent product quality.
• Ensure compliance with approved product specifications and applicable standards.
• Monitor critical parameters such as particle size, moisture content, bulk density, workability, open time, adhesion strength, and setting characteristics, as applicable to each product.
• Investigate customer complaints, production deviations, and quality failures; implement corrective and preventive actions.
• Ensure proper handling and storage of raw materials and finished goods to prevent moisture contamination.

D. Plant and Equipment Management

• Supervise the operation of mixers, ribbon blenders, paddle mixers, elevators, conveyors, vibratory screens, silos, dust collectors, and automatic packing machines.
• Coordinate with the maintenance team for preventive and breakdown maintenance.
• Reduce machine downtime and improve equipment reliability.
• Ensure proper calibration of weighing systems, load cells, and batching equipment.
• Maintain good housekeeping and equipment cleanliness to prevent cross-contamination.

E. Manpower Management

• Supervise production supervisors, machine operators, helpers, and packing personnel.
• Allocate manpower according to production schedules and operational requirements.
• Train employees on production procedures, equipment operation, quality requirements, and workplace safety.
• Monitor employee performance, attendance, productivity, and discipline.

F. Cost Control and Productivity Improvement

• Control raw material consumption, packing material usage, power consumption, and production losses.
• Monitor production cost per metric ton and identify opportunities for cost reduction.
• Improve plant productivity through process optimization and lean manufacturing practices.
• Track key performance indicators (KPIs), including production efficiency, rejection rate, downtime, and wastage.
• Prepare daily, weekly, and monthly production and consumption reports.

G. Safety and Compliance

• Ensure compliance with factory safety procedures, PPE requirements, and applicable environmental regulations.
• Maintain dust-control systems and safe handling procedures for cement, silica-containing materials, and chemical additives.
• Ensure safe material storage, equipment guarding, and adherence to lockout/tagout procedures where applicable.
• Maintain production records and support internal, customer, and statutory audits.

3. Required Skills and Competencies

• Strong knowledge of dry-mix mortar manufacturing processes.
• Practical experience with wall putty and tile adhesive production.
• Understanding of raw materials, formulations, batching, and mixing processes.
• Knowledge of production planning, inventory control, and manufacturing cost analysis.
• Experience in handling industrial mixers, packing machines, and material-handling systems.
• Strong leadership, problem-solving, and team-management skills.
• Proficiency in MS Excel, production reporting, and ERP systems.
• Ability to troubleshoot production and quality issues independently.

4. Key Performance Indicators (KPIs)

• Achievement of daily and monthly production targets.
• Production cost per metric ton.
• Raw material consumption versus standard formulation.
• Batch rejection, rework, and material wastage percentages.
• Equipment uptime and production downtime.
• On-time production completion and dispatch support.
• Finished product quality and customer complaint rate.
• Compliance with safety, housekeeping, and documentation standards.

5. Expected Candidate Profile

The ideal candidate should have hands-on experience in a dry-mix mortar or construction chemicals manufacturing plant, with the ability to independently manage production planning, manpower, raw materials, equipment, quality coordination, and plant performance.

Preference: Candidates with direct experience in wall putty and tile adhesive manufacturing, automated batching and mixing systems, and medium- to large-scale production facilities.