Plant Head

Job Purpose:

To lead the end-to-end operations of the cosmetic manufacturing plant, including production, planning, quality coordination, manpower management, and compliance. The role ensures that products are manufactured in accordance with GMP, hygiene standards, and regulatory norms, while optimizing cost, quality, and delivery timelines.

Key Responsibilities:

1. Production Management

• Manage daily operations of bulk manufacturing and filling/packing lines.
• Ensure compliance with batch manufacturing records (BMRs) and standard operating procedures (SOPs).
• Monitor production metrics such as output, yield, machine efficiency, and downtime.
• Maintain cleanliness and hygiene in production areas as per cosmetic GMP.

2. Production Planning and Control (PPC)

• Plan monthly and weekly production schedules based on sales forecasts, raw material availability, and inventory norms.
• Coordinate with procurement, stores, and dispatch for seamless supply chain management.
• Balance production loads across lines and shifts to meet deadlines without overutilization.

3. Quality & Regulatory Compliance

• Ensure all products are manufactured as per BIS / FDA / CDSCO cosmetic regulations and company specifications.
• Coordinate with QA/QC for in-process checks, batch validations, and regulatory documentation.
• Handle audits (internal, third-party, regulatory) and implement CAPA as required.

4. People Management

• Lead a team of supervisors, technicians, machine operators, and contract staff.
• Ensure proper training, shift planning, motivation, and skill development.
• Enforce discipline and adherence to SOPs and hygiene practices on the shop floor.

5. Process Optimization & Continuous Improvement

• Drive cost optimization through process improvement, waste reduction, and efficient resource utilization.
• Implement 5S, Kaizen, Lean tools to improve productivity and reduce batch changeover time.
• Evaluate and introduce automation where feasible (e.g., automated filling, labeling, etc.).

6. Maintenance & Equipment Coordination

• Liaise with the engineering/maintenance team for preventive and corrective maintenance.
• Maintain upkeep of key cosmetic production machinery: mixers, homogenizers, filling lines, conveyors, etc.

7. Safety, Hygiene & Environment

• Ensure adherence to safety norms, PPE usage, and hygiene practices on production lines.
• Conduct periodic safety drills and hygiene audits.
• Maintain a cleanroom environment (if applicable) for specialized formulations.

8. Reporting & Documentation

• Maintain production reports, batch records, shift logs, and dashboards.
• Present monthly MIS to management covering output, efficiency, manpower, and key challenges.

Key Skills & Competencies:

• In-depth knowledge of cosmetic formulations and GMP practices
• Excellent team leadership and interpersonal skills
• Strong command over production planning and cost control
• Regulatory awareness (BIS, CDSCO, FDA - India)
• Familiar with automated cosmetic filling and packaging machinery
• Working knowledge of ERP systems (SAP, Oracle, etc.)
• Ability to handle multi-SKU and batch-based production environments

KPIs (Key Performance Indicators):

• Batch completion vs plan
• Material yield and batch rejection rate
• Production efficiency (OEE)
• Hygiene and safety audit scores
• Line downtime and changeover time
• On-time delivery vs production schedule
• Manpower productivity
• Regulatory compliance readiness

Preferred Industry Experience:

• Cosmetic or personal care manufacturing (creams, lotions, gels, serums, oils, powders, etc.)
• Ayurvedic/herbal product plants (optional)
• FMCG production units with strict hygiene and batch control norms