Factory Manager

Viraat Industries; Nelamangala; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Viraat Industries in Nelamangala, Karnataka, seeks an experienced Production Manager to plan, manage and optimize the complete production operations for metal roofing sheets and sandwich panels, ensuring timely output and adherence to quality standards.

You will lead planning, scheduling, manpower, machine maintenance, safety and cost control, coordinating with Sales, Stores, Purchase, Quality and Dispatch to meet customer requirements and drive continuous improvement.

Qualifications

• Diploma / B.E. / B.Tech in Mechanical, Production, Industrial Engineering or related discipline.
• Additional qualification in Production Management will be an advantage.

Responsibilities

• Plan production schedules daily, weekly and monthly.
• Coordinate with Sales, Stores, Purchase, Quality and Dispatch for smooth flow.
• Monitor machine performance, production speed and efficiency.
• Lead safety and compliance initiatives.
• Prepare daily/weekly/monthly MIS reports.

Skills

Production Planning

Production Control

Manpower Management

Manufacturing Process Management

Material Consumption Control

Cost Control

Quality Control

Machine Utilization

Production MIS

Problem Solving

Team Management

Leadership

5S/Kaizen

Safety Management

Excel/ERP knowledge

Production costing basics

Education

Diploma / B.E. / B.Tech in Mechanical, Production, Industrial Engineering or related discipline

Job description

1. Job Purpose

To plan, manage and control the complete production operations of Viraat Industries to ensure timely production and dispatch of Metal Roofing Sheets and PU/PIR Sandwich Panels as per customer requirements, while achieving optimum productivity, quality, material utilization, manpower efficiency and cost control. The Production Manager will be responsible for effective utilization of production manpower, machinery, raw materials and other resources and for ensuring that production targets are achieved safely and efficiently.

2. Key Responsibilities

A. Production Planning & Scheduling

• Prepare daily, weekly and monthly production plans based on customer orders, dispatch schedules and available capacity.
• Coordinate with Sales, Stores, Purchase, Quality and Dispatch departments for smooth production flow.
• Plan production according to product specifications, sizes, thicknesses, colours and quantities.
• Prioritize urgent customer orders and ensure timely completion.
• Monitor production progress against the planned schedule.
• Take corrective action for production delays and bottlenecks.

B. Production Operations

• Supervise day-to-day production activities and ensure smooth functioning of the production line.
• Ensure production of metal roofing sheets and sandwich panels as per approved specifications.
• Monitor machine performance, production speed and operating efficiency.
• Ensure proper setting and operation of production machinery.
• Monitor output per shift and identify reasons for production shortfalls.
• Reduce machine idle time, waiting time and production bottlenecks.
• Ensure proper handover between shifts.

C. Raw Material & Material Utilization

• Coordinate with Stores and Purchase for availability of required raw materials.
• Ensure optimum utilization of coils, PU chemicals, accessories and other production materials.
• Monitor material consumption against standard/BOM.
• Control production wastage, scrap and rejection.
• Analyse reasons for excess consumption and take corrective action.
• Ensure proper identification, handling and storage of production materials.

D. Manpower Management

• Plan manpower requirements based on production schedules.
• Allocate workers/operators to machines and production activities.
• Monitor attendance, productivity and performance of production employees.
• Train operators and workers on machine operation and production procedures.
• Maintain discipline and ensure compliance with company rules.
• Develop multi-skilled manpower to reduce dependency on individual operators.
• Conduct daily toolbox meetings / production briefings wherever required.

E. Quality Control

• Ensure production is carried out strictly according to approved specifications and customer requirements.
• Coordinate with the Quality Department to maintain required quality standards.
• Monitor dimensions, thickness, length, coating, colour, density, bonding and other relevant product parameters.
• Identify and control production defects.
• Reduce rejection, rework and customer complaints.
• Implement corrective and preventive actions for recurring quality issues.
• Ensure first-piece approval wherever applicable.

F. Production Cost Control

• Control production costs through effective utilization of manpower, materials, power and machinery.
• Monitor material consumption and production yield.
• Compare actual production consumption with standard consumption.
• Identify major areas of production cost leakage.
• Reduce scrap, rework, rejection and unnecessary overtime.
• Work with the Accounts/Finance team for production cost analysis and costing data.

G. Machine & Maintenance Coordination

• Coordinate with the Maintenance Department for preventive and breakdown maintenance.
• Ensure machines are maintained in proper operating condition.
• Monitor machine breakdowns and production downtime.
• Maintain records of machine downtime and breakdown causes.
• Ensure preventive maintenance schedules are followed.
• Escalate major technical problems to Management/Maintenance immediately.

H. Safety & Compliance

• Ensure strict compliance with factory safety rules and procedures.
• Ensure workers use appropriate PPE.
• Conduct regular safety checks within the production area.
• Identify unsafe practices and conditions and take corrective action.
• Ensure safe handling of coils, chemicals, machinery and finished products.
• Report accidents, near misses and unsafe conditions to Management immediately.
• Ensure compliance with applicable factory and statutory safety requirements.

I. Inventory & Stores Coordination

• Coordinate with Stores for timely issue of raw materials to production.
• Ensure proper recording of material receipts, issues and returns.
• Monitor production WIP and finished goods.
• Avoid unnecessary accumulation of WIP.
• Ensure proper identification and segregation of rejected and usable materials.
• Coordinate with Dispatch for availability of finished goods as per delivery schedule.

J. Dispatch Coordination

• Coordinate with Dispatch to ensure finished goods are ready as per customer dispatch plans.
• Ensure production completion before committed dispatch dates.
• Verify product quantity and specifications before handing over to Dispatch.
• Support the Dispatch team in resolving production-related issues.

3. Daily Production Monitoring

The Production Manager shall monitor and report:

• Opening WIP
• Production target
• Actual production
• Production achievement %
• Machine-wise production
• Shift-wise production
• Manpower deployed
• Productivity per employee
• Raw material consumption
• Standard vs actual consumption
• Production wastage
• Scrap quantity
• Rejection quantity
• Rework quantity
• Machine downtime
• Breakdown hours
• Power consumption, where measurable
• Finished goods produced
• Pending production
• Dispatch-ready quantity
• Production-related customer issues

4. MIS & Reporting

The Production Manager shall prepare/submit the following reports:

Daily Reports

• Daily Production Report
• Machine-wise Production Report
• Shift-wise Production Report
• Raw Material Consumption Report
• Wastage/Scrap Report
• Rejection Report
• Machine Breakdown/Downtime Report
• Manpower Deployment Report

Weekly Reports

• Production Target vs Achievement
• Productivity Analysis
• Material Consumption Analysis
• Wastage & Rejection Analysis
• Machine Utilization Report
• Pending Production Report
• Production Bottleneck Report

Monthly Reports

• Monthly Production Performance
• Product-wise Production
• Production Cost Analysis
• Material Yield Analysis
• Wastage & Scrap Analysis
• Manpower Productivity
• Machine Utilization
• Rejection & Rework Analysis
• Production KPI Dashboard
• Corrective Action Status

5. Key Performance Indicators (KPIs)

The Production Manager will be evaluated based on:

Production Achievement Actual vs Planned Production Productivity. Output per Man-hour Machine Utilization Effective Machine Usage Material Yield Actual vs Standard Consumption Wastage Minimize Production Waste Rejection Reduce Defective Production Rework Minimize Rework Downtime Reduce Machine Downtime On-Time Production Complete Orders Within Schedule Labour Efficiency Optimize Manpower Production Cost Control Cost per Unit Quality Maintain Product Standards Safety Zero major safety incidents5S/Housekeeping Maintain Production Area Standards

6. Authority & Decision-Making

Major changes involving capital expenditure, manpower cost, major process changes, vendor changes or production policy shall require Management approval.

• Allocate production manpower.
• Assign operators to machines/workstations.
• Adjust production schedules within approved plans.
• Stop production where serious quality or safety issues are identified.
• Request maintenance intervention for machine problems.
• Recommend overtime based on production requirements.
• Recommend manpower requirements.
• Recommend disciplinary action for repeated production-related violations.
• Escalate material shortages, quality issues and production bottlenecks to Management.

7. Coordination With Other Departments

The Production Manager shall work closely with:

Sales: Customer order priorities and delivery commitments

Purchase: Raw material availability and purchase planning

Stores: Material issue, WIP and inventory control

Quality: Product quality, rejection and corrective actions

Maintenance: Machine breakdowns and preventive maintenance

Dispatch: Finished goods availability and dispatch schedules

Accounts & Finance: Production costing, consumption, wastage and MIS

HR/Admin: Manpower, attendance, overtime, training and discipline

8. Required Qualifications

• Diploma / B.E. / B.Tech in Mechanical, Production, Industrial Engineering or related discipline.
• Additional qualification in Production Management will be an advantage.
• Relevant experience in manufacturing/production operations preferred.

9. Experience

• 8-12 years of relevant production experience preferred.
• Experience in metal roofing sheets, PEB, sandwich panels, PU/PIR panels, sheet-metal or similar manufacturing industries will be preferred.
• Should have practical experience in handling production manpower, machinery and manufacturing processes.

10. Required Skills

• Production Planning
• Production Control
• Manpower Management
• Manufacturing Process Management
• Material Consumption Control
• Cost Control
• Quality Control
• Machine Utilization
• Production MIS
• Problem Solving
• Team Management
• Leadership
• 5S & Kaizen
• Safety Management
• Excel / ERP knowledge
• Basic understanding of production costing

11. Personal Competencies

• Strong leadership and team-management skills.
• Good communication skills.
• Ability to work under production deadlines.
• Strong problem-solving ability.
• Data-oriented approach.
• Ability to identify production inefficiencies.
• Discipline and accountability.
• Ability to coordinate with multiple departments.
• Hands-on approach to factory operations.
• Ability to work in shifts when required.

12. Expected Deliverables

The Production Manager is expected to ensure:

1. Production targets are achieved as per plan.
2. Customer orders are completed within committed timelines.
3. Production wastage and rejection are minimized.
4. Raw materials are utilized efficiently.
5. Machine downtime is controlled.
6. Labour productivity is continuously improved.
7. Product quality is maintained.
8. Production costs are controlled.
9. Production records and MIS are accurate and timely.
10. Safety and housekeeping standards are maintained.
11. Production processes are continuously improved.
12. Coordination between Production, Stores, Quality, Maintenance and Dispatch is effective.

13. Review & Reporting

The Production Manager shall conduct a daily production review meeting with relevant production personnel and submit the Daily Production Report to the Plant Head/Management. A weekly production performance review and monthly KPI review shall be conducted with Management to evaluate production achievement, productivity, material yield, wastage, rejection, downtime and production costs.