3.1 Production Planning & Efficiency

● Align the weekly production schedule with the sales forecast, order book and available machine capacity, and hold a daily production-vs-plan review with shift supervisors to resolve bottlenecks.

● Own the preventive maintenance calendar jointly with Engineering to cut unplanned downtime that erodes output; investigate and report shortfall root causes whenever variance exceeds 2% of plan.

● Optimise shift rostering and manpower allocation against the demand forecast to sustain capacity utilisation at 90% or above; resolve equipment breakdowns affecting capacity within 4 hours.

● Maintain and act on an OEE dashboard on critical lines; run root-cause analysis on the top downtime reasons monthly and roll out autonomous (operator-led) TPM maintenance checklists.

● Standardise changeover procedures, applying SMED principles, and track actual vs. target changeover time for every batch.

3.2 Quality Control

● Strengthen in-line inspection checkpoints at critical process stages and drive root-cause analysis for every batch breaching the rejection threshold.

● Deploy Statistical Process Control at critical control points and hold weekly quality huddles with line operators to sustain First Pass Yield.

● Update work instructions based on recurring defect trends and coordinate quality training with the QA function.

3.3 Cost & Yield Efficiency

● Validate theoretical yield benchmarks per product/recipe and run daily yield reconciliation and variance tracking.

● Investigate and correct the top yield-loss contributors, and audit green coffee handling, storage and input–output reconciliation to hold material loss within norm.





● Categorise rework reasons monthly, implement corrective action on the top recurring causes, and strengthen first-time-right controls at critical process stages.

3.4 Inventory & Supply Chain Coordination

● Align production planning with the sales order pipeline and run a daily dispatch-readiness review with warehouse/logistics to protect order fulfilment.

● Maintain an early-warning flag for orders at risk of delay and review fulfilment gaps monthly.

3.5 Food Safety & Compliance

● Conduct internal self-audits ahead of every external food-safety audit and close CAPAs from audit findings within seven days.

● Run monthly traceability mock recall drills and keep batch documentation complete and accurate for 100% traceability.

● Conduct weekly hygiene inspections and close non-conformances within 48 hours; keep GMP/HACCP training current.

3.6 Health, Safety & Setting

● Run daily safety walk-throughs and toolbox talks on the shop floor, and close near-miss/incident investigations within 48 hours.

● Conduct daily PPE compliance checks and counsel non-compliant employees on the spot; keep risk assessments for high-hazard areas current.

3.7 Manpower Productivity

● Lead manpower productivity studies and benchmarking, optimise manning levels and cross-skill operators for flexibility.

● Review and automate manual, low-value-add tasks where feasible to progress toward the FY26–27 output-per-employee target.

3.8 Continuous Improvement

● Sponsor Value Stream Mapping to identify non-value-added time and run Kaizen projects on identified bottlenecks.

● Review cycle-time trends in the monthly production review and recognise teams for improvement achievements.

📌 Manager Operations (Tirupati)
🏢 Tirupati
📍 Tirupati