Production Manager Pearlescent Pigment Manufacturing Plant

Company: Pearlescent Minchem (India) Pvt. Ltd.

Department: Production

Position: Production Manager

Reporting To: Plant Head / General Manager / Director

Location: Hosur, Tamil Nadu

Employment Type: Full-Time

1. Job Purpose The Production Manager will be responsible for the overall planning, execution, supervision, and control of manufacturing operations for pearlescent pigments and related mica-based products.

The candidate will be responsible for achieving production targets while maintaining consistent product quality, optimum chemical and raw-material consumption, minimum wastage, high plant efficiency, safe operations, and controlled manufacturing costs.

The Production Manager will work closely with QC/QA, Maintenance, Stores, Purchase, EHS and Management to ensure smooth and efficient plant operations.

2. Key Responsibilities

A. Production Planning & Execution

- Plan daily, weekly and monthly production according to customer orders and management targets.
- Prepare production schedules based on raw-material availability, plant capacity and delivery requirements.
- Ensure timely execution of production batches from mica preparation through coating, filtration/washing, drying, calcination and final processing/packing, as applicable.
- Monitor production progress against planned targets.
- Ensure optimum utilization of reactors, filters, dryers, calciners, furnaces and other production equipment.
- Identify production bottlenecks and take corrective action.
- Maintain proper batch-wise production records and traceability.

B. Process Control

- Ensure production is carried out strictly according to approved SOPs, batch sheets and process parameters.
- Monitor critical process parameters such as:

- Temperature
- pH

- Reaction time

- Chemical addition rate

- Agitation

- Filtration/washing conditions

- Drying conditions

- Calcination temperature and time

- Material moisture

- Batch yield
- Ensure consistency between batches.
- Work with QC/QA to investigate deviations and implement corrective actions.
- Develop and improve process parameters to increase product quality and production efficiency.

C. Chemical & Raw-Material Consumption A major responsibility of the Production Manager will be controlling manufacturing cost through efficient consumption of raw materials and chemicals.

- Monitor consumption of TiOCl, Sn compounds, NaOH, HCl and other process chemicals.
- Monitor mica, fuel, LPG/LDO, electricity and other consumables.
- Compare actual consumption against standard/BOM consumption.
- Investigate abnormal chemical consumption and material losses.
- Reduce process wastage and unnecessary chemical usage.
- Prepare monthly chemical consumption and production efficiency reports.
- Work with Management to establish and continuously improve standard consumption norms.

D. Production Yield & Cost Control

- Monitor batch-wise and monthly production yield.
- Analyse input vs. output quantity.
- Identify reasons for yield losses.
- Reduce rejection, rework and process losses.
- Monitor manufacturing cost per kg.
- Identify opportunities for reduction in:

- Chemical cost

- Fuel consumption

- Electricity consumption

- Labour cost

- Process losses

- Packing cost

- Downtime
- Suggest practical process improvements to Management.

E. Manpower Management

- Supervise production operators, helpers, technicians and other plant personnel.
- Allocate manpower according to production requirements.
- Prepare shift-wise manpower deployment.
- Ensure discipline,



attendance and proper work practices.
- Train operators on process SOPs, equipment operation, safety and quality requirements.
- Develop skilled operators who can independently handle critical processes.
- Evaluate operator performance and identify training requirements.

F. Equipment & Maintenance Coordination

- Ensure production equipment is operated correctly and efficiently.
- Coordinate with the Maintenance Department for preventive and breakdown maintenance.
- Minimize production downtime.
- Immediately report recurring equipment problems to Management/Maintenance.
- Participate in preventive-maintenance planning.
- Ensure reactors, pumps, filters, dryers, calciners, furnaces, agitators and other equipment are maintained in proper operating condition.

G. Quality Coordination

- Work closely with QC/QA to ensure every batch meets approved specifications.
- Ensure production batches are properly identified and traceable.
- Investigate customer complaints and internal quality deviations related to production.
- Implement corrective and preventive actions.
- Ensure rejected/off-spec material is properly identified and segregated.
- Maintain strict adherence to approved process parameters.

H. Safety & Environmental Responsibility

- Ensure all production activities are carried out safely.
- Ensure workers use appropriate PPE.
- Enforce safe handling and storage of acids, alkalis, titanium chemicals and other hazardous materials.
- Ensure safe operation of high-temperature equipment and furnaces/calciners.
- Follow company EHS procedures and statutory requirements.
- Report accidents, near misses and unsafe conditions immediately.
- Ensure good housekeeping and 5S practices throughout the production area.
- Coordinate with EHS/Management regarding effluent, wastewater and chemical waste handling.

I. Documentation & Reporting

Maintain and review

- Daily Production Report
- Batch Manufacturing Records
- Production Planning Sheet
- Raw Material Consumption Report
- Chemical Consumption Report
- Production Yield Report
- Rejection/Rework Report
- Machine Downtime Report
- Manpower Report
- Energy/Fuel Consumption Report
- Production Cost Report
- Process Deviation Reports
- Corrective Action Reports

Prepare daily, weekly and monthly production MIS for Management. 3. Key Performance Indicators (KPIs)

The Production Manager will be evaluated based on:

1. Achievement of monthly production targets.
2. Production cost per kg.
3. Chemical consumption per kg of finished product.
4. Raw-material yield.
5. Batch rejection percentage.
6. Rework percentage.
7. Machine utilization.
8. Production downtime.
9. LPG/fuel consumption per kg.
10. Electricity consumption per kg.
11. On-time completion of production plans.
12. Product quality consistency.
13. Reduction in process losses.
14. Manpower productivity.
15. Compliance with SOP, safety and quality requirements.

4. Candidate Profile

Education

- B.E./B.Tech./Diploma in Chemical Engineering, Mechanical Engineering, Production Engineering, Industrial Engineering or related field.
- Candidates with relevant manufacturing experience and strong practical knowledge may also be considered.

Experience Preferred: 510 years of experience in chemical, pigment, coating,



specialty chemical, mineral processing or similar manufacturing industries.

Experience in any of the following will be an advantage:

- Pearlescent pigment
- Titanium dioxide / TiO
- Mica processing
- Pigment manufacturing
- Chemical coating
- Wet chemical processing
- Calcination
- Filtration and drying
- Specialty chemicals
- Batch chemical manufacturing

5. Technical Skills Required The candidate should have practical knowledge of:

- Batch chemical manufacturing
- Chemical reaction processes
- pH and temperature control
- Chemical dosing
- Filtration and washing
- Drying processes
- Calcination/furnace operation
- Material balance
- Yield calculation
- Chemical consumption calculation
- Production planning
- Process optimization
- Equipment utilization
- Preventive maintenance coordination
- Industrial safety
- Excel and production MIS

Knowledge of ERP/MRP or production management software will be an advantage. 6. Desired Personal Qualities The ideal candidate should be:

- Strong in hands-on plant management
- Technically sound and practical
- Good at troubleshooting
- Data-oriented and analytical
- Cost-conscious
- Disciplined and responsible
- Solid in manpower handling
- Able to work under production pressure
- Proactive in identifying problems
- Good at communication and coordination
- Focused on continuous improvement
- Willing to spend substantial time on the shop floor

This is a hands-on production position and is not limited to office-based production planning. 7. Authority & Decision-Making The Production Manager will be authorized to:

- Allocate production manpower.
- Plan daily production activities.
- Adjust production schedules according to plant conditions.
- Stop unsafe production activities.
- Escalate quality/process deviations.
- Recommend changes in process parameters after proper evaluation.
- Recommend improvements in equipment, manpower and process methods.
- Recommend disciplinary/training actions for production personnel.

Major changes in formulation, process specifications, raw materials or production cost standards will require Management/QC approval. 8. First 90-Day Expectations

During the first three months, the Production Manager is expected to:

First 30 Days

- Understand all manufacturing processes.
- Study existing SOPs and batch records.
- Understand equipment and plant capacity.
- Understand chemical/raw-material consumption.
- Identify major production problems and bottlenecks.

3160 Days

- Establish reliable production monitoring.
- Improve manpower utilization.
- Start batch-wise consumption and yield analysis.
- Identify major sources of wastage.
- Improve production discipline and documentation.

61–90 Days

- Implement measurable process improvements.
- Reduce abnormal chemical consumption and process losses.
- Improve production efficiency and equipment utilization.
- Establish monthly production and cost KPIs.
- Submit a continuous-improvement plan to Management.

9. Important Note for Recruitment Priority should be given to candidates who have actually worked inside a chemical manufacturing plant and have hands-on experience in production operations, rather than candidates whose experience is primarily administrative or planning-oriented.

The selected candidate should be capable of personally troubleshooting production problems, analysing chemical consumption, controlling operators, understanding process chemistry and improving plant productivity.

Probation: 3–6 months.

Joining: Immediate / As mutually agreed.

Reporting Location: Hosur, Tamil Nadu.Role & responsibilities

📌 Production Manager (Hosur)
🏢 Pearlescent Minchem (India
📍 Hosur