– Factory Manager

Industry: Corrugated Packaging / Corrugated Boxes

Department: Factory Operations

Reporting To: General Manager / Managing Director

Location: Manufacturing Plant

Experience: 8–15 years in corrugation, packaging, paper converting or similar manufacturing industry

- Job Purpose To take complete responsibility for the day-to-day operation and performance of the factory and ensure that the plant achieves its targets for production, productivity, quality, wastage, cost, manpower utilization, maintenance, safety and on-time delivery.

The Factory Manager is responsible for maximizing machine utilization and factory profitability while maintaining customer quality and delivery commitments.
- Key Responsibilities

A. Production Management
- Plan and execute daily, weekly and monthly production as per sales orders and delivery requirements.
- Ensure maximum utilization of corrugation and converting machines.
- Achieve planned production tonnage within available machine hours.
- Implement shift-wise production planning.
- Minimize machine idle time, changeover time and production stoppages.
- Ensure proper sequencing of orders to improve productivity.
- Monitor production against plan every day.
- Ensure urgent customer orders are prioritized appropriately.
- Coordinate with Sales, Planning and Dispatch for smooth order execution.

B. Productivity Improvement
- Improve production output per machine hour.
- Improve employee productivity and manpower utilization.
- Establish machine-wise productivity standards.
- Monitor actual production versus standard production.
- Identify bottlenecks and implement corrective actions.
- Reduce setup/changeover time.
- Implement continuous improvement initiatives.

C. Corrugation Operations
- Ensure corrugator operates according to planned production hours.
- Monitor paper consumption, production yield and wastage.
- Control starch/glue consumption and ensure consistent bonding quality.
- Monitor flute quality, moisture, GSM and board parameters.




- Optimize paper combinations and machine settings.
- Reduce board wastage and trim loss.
- Ensure proper handling and storage of paper and finished boards.

D. Converting Operations
- Ensure printing, slotting, punching, folding, gluing and stitching operations are properly planned.
- Maximize utilization of printing and converting machines.
- Reduce setup and changeover time.
- Monitor machine-wise production and efficiency.
- Ensure minimum rejection and rework.
- Improve manpower productivity in converting operations.

E. Wastage & Cost Control
- Establish monthly wastage targets for each production section.
- Monitor paper wastage and conversion wastage daily.
- Identify reasons for excess wastage and implement corrective action.
- Control glue, ink, stitching wire and other consumables.
- Reduce rework and rejection.
- Monitor production cost per kg / ton.
- Continuously identify opportunities to reduce manufacturing cost.

F. Quality Management
- Ensure products are manufactured according to customer specifications.
- Maintain required box dimensions, GSM, BF, ECT/BCT, flute, printing and bonding standards.
- Reduce customer complaints, internal rejection and rework.
- Ensure proper quality checks at incoming, process and final stages.
- Work closely with the Quality team to identify root causes.
- Implement corrective and preventive actions.

G. Maintenance
- Ensure preventive maintenance is carried out as per schedule.
- Minimize machine breakdowns and unplanned downtime.
- Monitor machine-wise breakdown hours.
- Coordinate with Maintenance Manager for critical spare parts and repairs.
- Improve machine reliability and availability.




- Maintain proper records of breakdowns, preventive maintenance and machine performance.

H. Manpower Management
- Plan manpower according to production requirements.
- Optimize permanent and contract labour utilization.
- Monitor attendance, overtime and manpower productivity.
- Ensure proper deployment of employees between departments and shifts.
- Identify training requirements.
- Develop multi-skilled operators and workers.
- Maintain discipline and accountability within the factory.

I. Safety & Housekeeping
- Ensure strict compliance with factory safety procedures.
- Conduct regular safety inspections.
- Ensure PPE usage.
- Control unsafe practices and unsafe machine operations.
- Maintain proper housekeeping across production, warehouse and utility areas.
- Ensure fire safety and emergency procedures are followed.

J. Raw Material & Inventory Coordination
- Coordinate with Purchase and Stores for uninterrupted availability of paper and other raw materials.
- Monitor paper inventory and production requirements.
- Reduce excess and slow-moving inventory.
- Ensure proper storage and handling of paper.
- Control material damage and storage losses.

K. Dispatch & Delivery
- Coordinate with Dispatch to achieve 100% on-time delivery.
- Ensure completed orders are handed over to dispatch as per schedule.
- Prioritize production based on delivery commitments.
- Minimize finished goods waiting time.
- Coordinate with Sales when customer delivery priorities change.

L. Daily Management & Reporting The Factory Manager should conduct a daily production review covering:
- Production plan vs actual
- Machine hours vs available hours
- Machine downtime
- Production tonnage
- Productivity
- Paper consumption
- Wastage %
- Rejection %
- Rework
- Manpower attendance
- Overtime
- Maintenance breakdowns
- Pending orders
- Dispatch status
- Customer complaints A daily factory performance report should be submitted to management.

📌 Factory Manager (Chennai)
🏢 Velammal Educational Trust
📍 Chennai