Job Description

Plant Manager – Dairy Industry

Position Title: Plant Manager

Industry: Dairy / Food Processing

Location: Singavaram

Reports To: Vice President – Operations / Head – Manufacturing

Experience: 10–15 Years

Qualification: B.E / B.Tech ( Food Technology/ Dairy Technology)

1. Role Purpose

The Plant Manager is responsible for overall leadership, performance, and statutory compliance of the dairy manufacturing plant. The role ensures safe, efficient, cost-effective, and quality-driven operations while achieving business KPIs related to production, yield, cost, energy, safety, people development, and continuous improvement. The Plant Manager acts as the single-point owner of plant performance and governance.

2. Key Responsibilities

A. Overall Plant Operations & Governance

Lead end-to-end plant operations including milk procurement interface, processing, packaging, utilities, maintenance, quality, stores, logistics, and dispatch.
Ensure uninterrupted production while maintaining the highest standards of safety, quality, and compliance.
Drive plant performance in line with annual business plans, budgets, and strategic objectives.
Act as the custodian of plant discipline, culture, and operational rigor.

B. Dairy Processing & Production Excellence

Oversee all dairy processing operations including:
Milk Reception, Pasteurization, Homogenization, Separation
Evaporators, High-Pressure Pumps, CIP Systems
Packaging & Filling Lines
Ensure optimal capacity utilization, yield maximization, and loss reduction.
Review production planning, execution, and dispatch adherence on a daily basis.
Lead root cause analysis for deviations in output, quality, or efficiencies.

C. Utilities, Engineering & Asset Management

Take full ownership of utilities including:
Boilers & Steam Systems
Refrigeration (Ammonia & Freon)
DG Sets, Electrical Systems, VAM
Compressed Air, RO/UF, ETP/STP & water management
Ensure high equipment availability through robust preventive, predictive, and reliability maintenance systems.
Approve maintenance strategies, spares planning, shutdown management, and asset life-cycle optimization.

D. Quality, Food Safety & Regulatory Compliance

Ensure 100% compliance with:
FSSAI, HACCP, GMP, ISO, FSSC 22000
Factory Act, Boiler Act, Electrical Safety norms
Pollution Control Board and environmental regulations
Promote a strong food safety culture across the plant.
Drive reduction of customer complaints and ensure product consistency and traceability.

E. Operational Excellence & KPI Ownership

Own and review plant KPIs including:
OEE, Line Efficiency, Yield, Wastage
Energy & Water Consumption
Plant Downtime, Safety Metrics, Customer Complaints
Implement Lean Manufacturing, TPM, WCM, and Continuous Improvement initiatives.
Sponsor automation, digitization, and Industry 4.0 initiatives.
Use data-driven decision-making to improve plant performance.

F. Budgeting, Cost Control & Energy Management

Prepare and manage annual plant budgets and forecasts.
Control operating costs related to utilities, manpower, spares, packaging, and consumables.
Drive energy-saving and sustainability initiatives to meet corporate benchmarks.
Improve profitability through productivity and efficiency improvement projects.

G. People Leadership & Organizational Development

Lead and develop a multi-disciplinary team of 100–300 employees.
Build strong succession planning for critical plant roles.
Conduct performance reviews, capability development, and leadership coaching.
Promote a culture of safety, accountability, teamwork, and continuous improvement.
Ensure harmonious industrial relations and disciplined workforce behavior.

H. Government Liaison & Statutory Interface

Serve as the primary point of contact with:
Factory Inspectorate
Boiler Directorate
Electrical Inspector
Pollution Control Board
Local authorities and auditors
Ensure timely renewals, audits, inspections, and statutory reporting.
Zero tolerance for legal or safety non-compliance.

I. Projects, CapEx & Expansion

Lead CapEx planning and execution for:
New processing or packaging lines
Capacity expansion and layout optimization
Automation and digital transformation projects
Oversee equipment selection, installation, commissioning, and stabilization.
Evaluate new technologies including AI/ML for predictive maintenance and energy optimization.

3. Mandatory Skills

End-to-End Dairy Plant Management
Dairy Processing & Utilities Expertise
Strong Knowledge of Food Safety & Compliance
Budgeting, Cost & Energy Management
KPI Ownership & Lean / TPM Implementation
Government Liaison & Statutory Compliance
Strong People Leadership & IR Management

4. Preferred Certifications

TPM / WCM Expert
Six Sigma (Green / Black Belt)
Certified Energy Manager / Energy Auditor
HACCP / FSSC 22000 Lead Auditor
RCA / Predictive Maintenance Tools

5. Competencies Required

Strategic & Systems Thinking
Strong Leadership & Decision-Making
High Ownership & Accountability
Analytical & Problem-Solving Ability
Excellent Communication & Stakeholder Management
Change Management & Execution Excellence

Plant manager