JM Production

IFFCO • Burgul, Hyderabad, India • 1w ago

Job Summary

To oversee daily production operations at the non-dairy creams manufacturing plant utilizing UHT processing, ensuring that output consistently meets quality, safety, and environmental standards while operating within defined budgetary limits. The role is responsible for optimizing resource utilization, improving operational efficiency, and ensuring full compliance with regulatory requirements and company policies.

Roles & Responsibilities

Lead day-to-day operations of the production floor to meet output targets, quality parameters, and compliance benchmarks.
Operate and supervise UHT (Ultra High Temperature) and HTST (High Temperature Short Time) processing systems for non-dairy cream production.
Manage key equipment such as homogenizers, pasteurizers, cream separators, heat exchangers, and aseptic/non-aseptic valve systems.
Ensure maintenance and sanitation practices comply with Tetra Pak standards, GMP, and industry hygiene regulations.
Optimize man-machine utilization to meet production goals within time and cost targets.
Ensure strict adherence to quality systems (GMP, QMS), including the monitoring and control of CPs and CCPs.
Drive reduction of utilities and inputs (water, electricity, consumables, raw materials) through efficient plant operations.
Supervise the installation and commissioning of new equipment; validate performance per technical specifications.
Lead and mentor a team of technicians and contract staff; conduct training and promote a strong safety and quality culture.
Conduct root cause analyses (RCA) and Why-Why analysis for breakdowns and deviations; implement CAPA to prevent recurrence.
Implement and promote continuous improvement initiatives using 5S, Kaizen, and Lean Manufacturing principles.
Prepare and submit production, downtime, and maintenance reports, including daily MIS and CEO dashboards.
Ensure accurate data entry in SAP for production activities; manage cycle counting and variance reporting.
Minimize in-process losses and wastage of raw materials, packaging materials, and finished goods.
Support and maintain critical processes related to cream operations and associated utilities.
Coordinate with OEMs, vendors, and regulatory authorities for audits, maintenance schedules, and spare parts management.
Ensure compliance with all HSE policies, conduct risk assessments, implement SOPs, and enforce zero-accident safety standards.
Allocate daily tasks, conduct performance reviews, and support team engagement and workforce planning.

KPIs

Production output vs. plan
Yield optimization and cost per liter
Online and offline wastage reduction
Audit readiness and CAPA closure rates
Technician performance and skill development
Utility consumption efficiency
SAP reporting accuracy and cycle count compliance

Work experience requirement

10+ years of experience in production and/or maintenance in non-dairy UHT and Tetra Pak-based operations.
Minimum 3 years in a leadership or supervisory role.
Strong technical understanding of UHT/HTST, homogenization, cream separation, aseptic systems, and related processes.
Familiarity with CIP (Clean-in-Place) systems and operations within GMP/HACCP frameworks.
Hands-on experience with utility systems essential to food/dairy manufacturing.
Experience working with Tetra Pak
Proficient in SAP and standard reporting tools for manufacturing operations.
Strong team leadership, troubleshooting, and documentation skills.