Manager - Manufacturing Operations

Job Title:
Manager - Manufacturing

Job Type:
Permanent, Full-time

Function:
PSO -Manufacturing

Business:
Godrej Consumer Products Limited

Location
:
Gwalior, M.P.

About Godrej Industries Group
We have significant interests in consumer goods, real estate, agriculture, chemicals, and financial services through our subsidiary and associate companies, across 18 countries.

About Godrej Consumer Products Limited (GCPL)
Godrej Consumer Products is a leading emerging markets company. As part of the over 125-year young Godrej Group, we are fortunate to have a proud legacy built on the strong values of trust, integrity and respect for others. At the same time, we are growing fast and have exciting, ambitious aspirations.

Today, our Group enjoys the patronage of 1.2 billion consumers globally, across different businesses. We rank among the largest Household Insecticide and Hair Care players in emerging markets. In Household Insecticides, we are the leader in India, the second largest player in Indonesia and are expanding our footprint in Africa. We are the leader in serving the Hair Care needs of women of African descent, the number one player in Hair Colour in India and Sub-Saharan Africa, and among the leading players in Latin America. We rank number two in Soaps in India and are the number one player in Air Fresheners and Wet Tissues in Indonesia.

Innovation is a key driver of our strategy, and we are constantly looking to delight our consumers with exciting, superior quality products at affordable prices. We were the highest ranked Indian company on Forbes' list of The World's 100 Most Innovative Growth Companies 2015, for the second year in a row.

About The Role
As Manager/DGM – Manufacturing, you will lead the operations of a multi-category manufacturing facility with respect to best-in-class design standards, productivity, procurement, delivery & safety practices.

Key Responsibilities

• Ensure implementation of policies and procedures in the manufacturing activities of the concerned plant
• Comply with all statutory requirements and other compliances related to Electricity, Pollution & Environment, Factories act, Legal Metrology, Labour laws, FDA & Insecticides act, EPR & PWM etc
• Ensure implementation of Quality (ISO, CGMP, HACCP) and SHE standards (ISO and GCPL Standards)
• Maintain plant and related machinery to increase availability & MTBF, reduce downtime & MTTR.
• Improve Manpower and Machine productivity to best-in-class levels
• Develop operational plans and monitor day-to-day operations for production for multiple products, processes and shifts by coordinating with other depts like procurement, quality, stores and HR.
• Ensure achievement of production targets as per rolling plan and dispatch schedules as per quality specifications with continuous process improvements
• Reduce process wastages, rework and rejections and improve process yield to ensure costs, efficiencies variances are within norms.
• Reduce quality defects in incoming, in process and final stages of operation.
• Reduce first aid and other safety incidents.
• Lead initiatives for reducing energy, water and plastic consumption and other sustainability & green initiatives.
• Lead major infrastructure initiatives such as plant expansion, layout changes, installation of equipment, capability / capacity enhancement, cost reduction, etc
• Ensure faster ramp up, stabilization and production of NPDs as per launch plan.
• Control and monitor manufacturing expenses and ensure the fixed, variable and capital costs are controlled within the budget.
• Provide leadership through 'Total Employee Engagement' framework.
• Promote Inclusion and Diversity in Work
• Lead implementation of all Manufacturing excellence initiatives like 5S, Kaizen, Lean, TPM and Six sigma and lead the teams for participating in external forums and competitions.
• Lead all internal and external audits for the plant and close the deviations on time.
• Promote peaceful and harmonious relation with all the labour, staff, union bodies and external Govt. and NGO bodies in line with the company vision.
• Participate in the appraisal process of all direct reportees
• Collaborate with peer plant operations managers to share best practices.
• Maintain effective shop floor discipline.
• Reduce inventory and obsolescence of Spares, WIP & FG in the factory.
• Ensure timely capitalization of assets, closure of advances paid to vendors.
• Recruit Train, Develop and Evaluate Operations Staff from time to time.
• Manage and provide leadership support to the overall manufacturing Operations of the organization
• Manage critical situations in the plant and remove constraints through possibility thinking.
• Ensure the implementation of the latest technologies in the industry with suitably applicable IoT, Industry 4.0, Automation and digitization to reduce production costs.
• Finalize Technically Qualified User Required Specification (URS), Evaluate qualifying criteria for URS, and close observations with suppliers.
• Develop and implement a risk management plan to identify, assess, and mitigate potential risks in the plant.
• Coordinate with internal teams for implementation of CSR programs
• Collaborate with HR team, participate in wage negotiations & other discussions with worker unions and conclude the wage settlement within the approved budget.
• Negotiate and finalise the conversion charges of subcontractors within the approved budgets.
• Improve the service levels of subcontractors and other contractors with respect to quality, environment, delivery and safety targets of the organization.

Expected Delivery

• Ensure "Zero Injury" in plant operations.
• Drive leadership through people management, discipline, development, promotions, and motivation within a changing environment
• Develop annual Factory plan and ensure delivery of production volumes at desired levels of cost efficiencies and product mix
• Meet productivity goals and other KPIs set for the plant through continuous improvement initiatives.
• Ensure adherence to budgeted plant Costs Efficiencies – Fixed, variable and capex Costs, Material Variances, Overheads, Re-work, wastages, etc.
• Deliver key operational goals including safety, quality, cost, operating plant efficiency, and waste reduction.
• Lead and direct process improvement, problem solving, and crisis management for operational issues.
• Prepare a safety accident prevention plan for the site in line with the corporate safety plan for excellence including BCP/DRP, Risk mitigation & Crisis management, Onsite emergency plan.
• Plan and implement a comprehensive quality control system for all aspects of the plant.
• Establish and maintain effective communication channels with all stakeholders, including contractors, vendors, team members, and management.
• Regularly report on plant status and progress to senior management and stakeholders, including updates on budget, major plant KPIs, critical project timeline and risk management.
• Foster a culture of collaboration, innovation, and continuous improvement among plant team and stakeholders.
• Identify and leverage opportunities to streamline processes, reduce costs, and improve plant efficiency without compromising quality or safety.
• Develop and maintain a risk management plan, identifying and addressing potential risks and developing contingency plans to mitigate those risks.

Budget Responsibility

• Manage budgetary responsibilities with respect to the allocated budget for the Greenfield / Brownfield project expansions, Capital spends, Material wastages, Fixed overheads, Manpower nos and costs.
• Identify and prepare any other budgetary requirements with relevant stakeholders.
• Ensure delivery within the approved project budget at all times.
• Anticipate budget over-run in advance and appraise relevant stakeholders proactively, wherever applicable

Who are we looking for?

Education, Experience & Knowledge

• Graduate in Engineering in Mechanical / Electrical / Chemical (Masters / MBA in Operations preferred)
• More than 10 years of relevant experience in Manufacturing Operations preferably in the FMCG, Beverages, Pharmaceuticals or other Consumer Goods industries.
• Thorough knowledge of Operations Management of a manufacturing facility
• Knowledge of state and federal regulations, i.e. OSHA, FDA, EPA, Factories act etc.
• Knowledge of industry practices in construction safety and Environment management
• Well-versed with 5S, Kaizen, Lean manufacturing, TPM, TQM, etc.
• Leading large teams and rich experience in managing workers, unions etc
• Knowledge of Safety policies, quality management, housekeeping requirements, statutory requirements
• Knowledge of IoT, Industry 4.0, Digitization, Data Capturing etc
• Demonstrated track record of successfully implementing strategic partnership development, team building, performance management & change management for teams.
• Ability to develop a deep understanding of operating business units.
• Ability to plan in a structured way for smooth execution.
• Ability to assess risks, plan mitigating actions and handle critical situations.
• Proficiency in MS project, Zoho or similar planning software
• Knowledge in MS Office especially Excel, AutoCAD etc.

Key Skills

• Create Business Solutions
• Exhibit a sense of urgency with lean thinking to optimize the men, machine, and material by using lean sigma tools for to improve operational effciencies
• Plan in advance for new technologies to improve process capability and plant availability.
• Strong influencing skills at all levels (including senior levels)
• Ability to lead and deliver sustainable solutions.
• Strong Communication skills with multiple stakeholders including Union representatives.
• Good inter-personal skills and effective communication skills
• Strong verbal & written communication / presentation skills including effective use of PowerPoint, Excel, Word, etc.
• Ability to lead people for smooth functioning with timely inputs.
• Ability to implement change management and lead innovation.
• Drive the change for implementing SMART Factory fundamentals.
• Ability to troubleshoot and solve complex problems with strong analytical and technical thought process.
• Comfortable working in a matrixed organization

What's in it for you?

Be an equal parent
Maternity support, including paid leave ahead of statutory guidelines, and flexible work options on return

Paternity support, including paid leave

New mothers can bring a caregiver and children under a year old, on work travel

Adoption support; gender neutral and based on the primary caregiver, with paid leave options

No place for discrimination at Godrej
Gender-neutral anti-harassment policy

Same sex partner benefits at par with married spouses

Gender transition support

We Are Selfish About Your Wellness
Comprehensive health insurance plans, as well as accident coverage for you and your family, with top-up options

Uncapped sick leave

Mental wellness and self-care programmes, resources and counselling

Celebrating wins, the Godrej Way
Structured recognition platforms for individual, team and business-level achievements

Performance-based earning opportunities

An inclusive Godrej
Before you go, there is something important we want to highlight. There is no place for discrimination at Godrej. Diversity is the philosophy of who we are as a company. And has been for over a century. It ' s not just in our DNA and nice to do. Being more diverse - especially having our team members reflect the diversity of our businesses and communities - helps us innovate better and grow faster. We hope this resonates with you.

We take pride in being an equal opportunities employer. We recognise merit and encourage diversity. We do not tolerate any form of discrimination on the basis of nationality, race, colour, religion, caste, gender identity or expression, sexual orientation, disability, age, or marital status and ensure equal opportunities for all our team members.

If this sounds like a role for you, apply now

We look forward to meeting you.