The Deputy Head of Manufacturing supports the Head of Operations in overseeing full-scale plant operations across refinery, soap, and detergent production units. The role ensures seamless production execution, operational discipline, quality compliance, maintenance coordination, and resource optimization. This position is responsible for production planning, monitoring KPIs, minimizing stock variances, and driving efficiency improvements and cost-saving initiatives across the manufacturing processes. The role requires strong technical knowledge, leadership capability, and experience in multi-product manufacturing environments.
Key Responsibilities
Production & Operations Leadership
- Supervise and coordinate daily operations across refinery, soap, and detergent production lines.
- Ensure production targets are achieved while maintaining quality, safety, and cost efficiency.
- Monitor and optimize process parameters to maintain consistent product quality and operational stability.
- Support capacity planning, production scheduling, and raw material utilization.
- Oversee shift operations, manpower planning, and workforce productivity.
Stock Variance & Material Accountability
- Lead stock monitoring processes for raw materials, work-in-progress (WIP), and finished goods.
- Review and validate daily, weekly, and monthly stock variance reports.
- Conduct root-cause analysis for deviations and implement corrective and preventive actions.
- Strengthen internal controls to improve material balance accuracy from input to output.
- Coordinate with supply chain, warehouse, and finance teams for accurate reporting and reconciliation.
Efficiency, Performance Improvement & Optimization
- Monitor key operational KPIs: yield, recovery, OEE (Overall Equipment Effectiveness), energy usage, batch cycle time, and productivity.
- Identify gaps in processes and drive continuous improvement projects (Lean, Six Sigma, TPM - Total Productive Maintenance).
- Reduce manufacturing losses, improve throughput, and enhance overall plant performance.
- Implement digital monitoring systems and support automation initiatives.
Maintenance Coordination
- Collaborate with maintenance teams to ensure preventive, predictive, and breakdown maintenance is executed on time.
- Minimize unplanned downtime and ensure equipment reliability and availability.
- Participate in shutdown planning, execution, and post-analysis.
- Ensure all equipment and utilities comply with operational and safety standards.
Quality, Safety & Compliance
- Ensure all products meet internal quality specifications and industry regulatory standards.
- Support the implementation of Good Manufacturing Practices (GMP) and Standard Operating Procedures (SOPs).
- Conduct regular audits on process quality, hygiene, safety, and housekeeping.
- Promote a strong culture of safety, discipline, and compliance across the plant.
Reporting & Documentation
- Prepare and review daily, weekly, and monthly production performance reports.
- Present variance analysis, efficiency metrics, downtime reports, and improvement updates to management.
- Ensure timely and accurate documentation of process records, deviations, and compliance reports.
- Analyze trends and recommend data-driven solutions for process improvement.
Cost Reduction & Continuous Improvement
- Identify cost-saving opportunities across raw materials, utilities, manpower, and process optimization.
- Lead cross-functional cost reduction and waste minimization projects.
- Implement process automation and productivity enhancement initiatives.
- Benchmark processes with industry standards to ensure competitive manufacturing costs.
Leadership & Team Development
- Mentor production managers, supervisors, and operators to build technical competency.
- Drive training programs focused on safety, quality, process improvement, and equipment handling.
- Promote a culture of teamwork, accountability, and continuous improvement.
Qualifications & Experience
- Education: Bachelor’s degree in Chemical Engineering, Industrial Engineering, Mechanical Engineering, or a related field (Master’s preferred).
- Experience: 8–10+ years of experience in manufacturing operations, preferably in Refinery, Soap, Detergent, or Process Chemical industries.
- Technical Knowledge: Strong technical understanding of refining operations, saponification, detergent processing, and filling & packaging lines.
- Expertise: Proven expertise in production planning, process control, stock variance management, and efficiency improvement.
- Methodologies: Familiarity with Lean, TPM, Six Sigma, and continuous improvement methodologies.
- Systems: Experience working with CMMS, ERP, and manufacturing analytics systems.
