Mfg Process Ops Team Lead

Overview:

Purpose/ Key Role

Ensuring support to manufacturing manager in meeting the production targets, SA along with optimum efficiencies.

Co-coordinating with manager in deciding the optimum capacity utilization across lines and SKU combinations for the shift based on the capacities and dispatch priorities - communication the packaging leader of the plan and develop them working jointly to sustain key packaging deliverables in line with AOP.

Ensuring minimal waste + rejects and maximum capacity utilization in shift.

Ensuring smooth and efficient running of all lines and minimum downtime.

Ensuring Zero debate BBS related best practices & SOPs are followed by operators. No LTA/ fire incident in manufacturing.

Why-why analysis of all the process related issues and closing actions with Engineering within agreed timeline.

Ensuring compliance of all the Key controls.

Clearing AIB, safety, M&W related audits with no NC in manufacturing.

Ensuring all quality related parameters are met during production

Ensuring timely information to Argo in case of potato related quality problems and Quality Dept. in case of any other quality related problems identified online and timely clearance of hold materials.

Ensuring shop-floor hygiene, food safety, product quality, packaging quality, TPM circles, Safety at the top during operation all the time

Preparing the daily manpower plan for the permanent workers based on the production plan – preparing the shift roster and displaying it on the notice board.

Preparing the manpower plan for contract workers daily balancing idle line capacity.

Redeploying people based on competencies or gaps identified at a particular workstation to build the capability of people and line.

Ensuring timely, accurate updating and maintenance of information related to department performance.

Ensuring disruption free operation by addressing shop-floor dispute of workers and don’t let such arguments to crop up as IR issues/unionized issues.

Shop-floor communications on various targets, opportunities area, market feedback, month’s targets, score cards etc. Motivating shop floor team, exploring R&R sessions& make the team participative to key agendas of plant.

Ensure adherence to core PepsiCo processes like KP

Responsibilities:

Roles and Responsibility

Safety

Implement safety standards and drive safety culture.

Participate in safety meetings and close the agreed recommendations within agreed timeline.

Work with SHE pillar and safety coordinator on implementing the Safety related action points and working to ensure Zero LTA in the plant.

Execute safety and sustainability capex and initiatives.

Sustainability

Track, monitor and report sustainability KPIs - EUR and WUR

Drive sustainability agenda and take essential steps to achieve goals.

Drive new sustainability project trials through continuous improvement

People Management

Deployment of workmen on respective workstations as per plan

driving the agenda for DL, developing backups on redeployment matrix to impact on manpower productivity. Regular coordination with HR on tracking unauthorized absenteeism and OT trend and ensuring effective communication to sustain good discipline.

Production Deliverables

Ensuring compliance to weekly/ monthly production targets as per PepsiCo quality and hygiene standards, delivering AVC over & above AOP.

Maximising TE/ NE , ensuring conversion efficiencies better than AOP and executing ideas on productivity.

sharing views with sector SMEs for troubleshooting and capturing better productivity ideas implemented across other plants as a part of continuous improvement.

Coordinating & planning with cross functional team members to ensure seamless production.

Capacity Utilization

Running the lines with best NE TE by monitoring & reducing NE TE losses & utilizing manpower planning in line with actual plan a capacity.

Waste Management

Ensuring minimal wastage, recirculation ideas, optimum manpower utilization and operating at maximum efficiencies.

Driving for “ZERO Loss” mantra for the lines with the help of sector team and by utilizing TPM tools & ensuring cross functional involvement (focusing on JH culture on shop floor).

Planning and Reporting

Ensuring integrity of data entry across lines, monitoring the data on shift to shift basis and reporting of the all the numbers on daily bases for the best control on the line.

IR Management

Ensuring line discipline during production – OT, Absenteeism control, motivating the teams for the positive environment at the shop floor.

Conducting 1-1 with the operatives, conducting ZOZi sessions for the self and implementation of “Each one teach one”, “KPL” etc on the shop floor for the better engagement and building inclusive culture & keeping the operation disruption free

Support to Cross function

Enabling effective coordination with support functions & implementation of a quality,

hygiene, safety & TPM culture that promotes company growth.

Also ensuring the “Why Why Analysis” of b/d on timely manner. Need to ensure control on consumable cost.

SAP Management

Batch closing and stock verification in Day store, taking care of GCS, SOX audit and KC compliances.

Ensuring inventory management by proper transferring of FG and taking RM by proper hand shaking between the cross functional departments.

NPD Handling

Ensuring compliance to all NPD production, reference and Gold sample production on timely manner with AOP efficiency numbers.

Ensuring proper feedback to R&D to build upon the current standards.

Cost Management

controlling the consumables, parts change management and developing new vendors for the reduction in consumables, better quality of parts at the engineering stores with close coordination with engineering team and engineering store person and sensitizing the shop floor team.

Acting as a reliever

Relieving Shift In-charges as and when required.

M&W and other audit

Acting as a manufacturing control owner/ representative of MNW data; quality & safety audit.

New projects

Acting as manufacturing representative for upcoming new projects.

Statutory Compliances

Prepare statutory calendar and ensure implementation.

Electricity act, The Air (Prevention and Control of Pollution) Act, The Legal Metrology Act, The Explosives Act, The Petroleum Act, The Water (Prevention and Control of Pollution) Act, The Factories Act,

Learning

Seeking feedback from seniors and peers

Reflecting on own competencies and possible gaps

Setting learning goals in consultation with seniors

Monitoring implementation of these goals

Continuously updating knowledge from outside environment

Develop in-depth understanding of MIS, VMOH, MOR etc.

Qualifications:

Qualifications & Experience

BE/BTech in Mechanical / Electrical / Chemical / Food Technology with minimum 6-8 years of experience in a FMCG / Food industry desirable.

Sound Process & equipment knowledge

Improvement projects experience

Experience of working in shifts

Knowledge of manufacturing and packaging

Good Communication and negotiation skills