Production Manager

Our client is seeking an experienced Production Manager to join their team.

Responsibilities:

1. Ensure that no milk remains in a raw milk silo for more than 24 hours and that no milk remains in a processed milk silo for more than 60 hours (2.5 days).
2. Ensure that milk is processed according to the standards laid down by the relevant Food safety and HACCP procedures.
3. Processed products comply with legislated standards in terms of Pasteurisation, Butterfat%, freezing point and micro results.
4. Butterfat of processed product to be tested every 30 minutes.
5. Daily diversion valve testing (CCP) is conducted, monitored and recorded.
6. Records are to be reviewed daily, signed off and filed.
7. Ensure that sufficient stock of each product type is processed and packed every day, dependent on milk supply.
8. Ensure there is sufficient packaging to meet the demand for products.
9. Ensure production stock items such as Freeze Dried Culture never fall below minimum stock levels.
10. All packaged products comply with legislated standards in terms of micro results.
11. Packaging and production losses are to be kept within the agreed target.
12. Ensure that there is sufficient packaging material stock levels at all times.
13. Ensure that the production stock controller captures the correct stock figures and that these are then captured onto D3.
14. Reconcile all production stock daily and at month end.
15. Monitor raw milk levels and inform relevant people if any supply constraints appear.
16. Start packing at 07:00 am.
17. Monitor that the correct expiry dates and batch codes are printed on each product daily to ensure full traceability of the product.
18. Ensure that each product is packed in correctly labelled packaging.
19. Packaging suppliers to have full traceability of their packaging linked to DDD batch codes and or for date of packing.
20. To ensure that a full Product recall can be conducted using the batch code.
21. Suppliers of packaging to provide COA’s for all packaging material used.
22. MSDS and Technical data to be provided by all Packaging material suppliers.
23. On filling, caps are seated correctly to prevent leaking.
24. Machine operators check that the weights are correct at start up.
25. Under filled and uncapped bottles to be removed and the product set aside for reworking.
26. No manual capping of bottles unless it is due to a breakdown; capping must then be closely monitored, supervised and documented.
27. Employees capping must:
1. First wash hands and sanitise.
2. Not to touch bottle neck thread.
3. Only be responsible for capping.
4. Not pick up, touch or pack crates.
28. No manual topping up of bottles.
29. Correct CIP programmes to be used for cleaning of the various processing plant equipment, silos and tanks.
30. CIP samples are to be sent to the Laboratory to be checked.
31. Supervise that manual cleaning is done as per cleaning schedules and procedures to ensure equipment is clean and to prevent contamination of product in processing and packaging.
32. Ensure that the correct colour coded brushware is available and used for cleaning.
33. Correct chemicals and dilutions are used for:
1. Balance tank dosing.
2. Sanitiser Baths.
3. Foamer.
34. Machine operators are held responsible for cleaning their own machines and areas between products and at the end of each day.
35. Pipes and nozzles are cleaned before being placed in the sanitiser baths. All air must be removed from the pipes when placed in the Baths.
36. Supervise that pre production, filling machine pipes and nozzles are sanitised prior to set up and Machine is then steamed.
37. Weekly deep cleaning of all filling machines and butter machine, conveyors and surfaces.
38. Incoming pallets are clean.
39. To be familiar and comply with Production, Food Safety / HACCP and other relevant Company policies and procedures.
40. Monitor employees to ensure that they adhere to the policies and procedures.
41. Ensure that the daily, weekly & monthly checklists are completed as required:
1. CIP.
2. CCP monitoring of pasteurisation times and temperatures.
3. Temperature monitoring of raw and processed milk silos.
4. Cleaning checklists for tankers, CIP, processing plant, production areas and filling machines.
5. Product traceability.
6. Personal hygiene register and that all staff are checked daily to ensure that they comply.
7. Glass and hard plastic controlled and monitored and recorded.
42. Liaise with the Technical manager to ensure there is a service & maintenance plan for all plant equipment within your department.
43. Inform Technical department of plant break downs timeously.
44. Liaise with Technical Manager regarding timing of planned and unplanned plant servicing.
45. Maintaining control of tools, lubricants and toners that are used by factory staff during production.
46. Ensure that all new employees attend the relevant Food Safety and HACCP training.
47. Annual food safety refresher training to be attended by all staff.
48. No new or temporary employee is to be permitted to work in the factory unless they have received at least the following training:
1. Personal hygiene requirements
2. Hand washing
3. Wearing of correct captive gear
49. To keep updated with relevant industry changes.
50. Plan and request training for staff or for self development.
51. To fully understand the workings of the D3 software program, relevant to the running of the department including:
1. Raw milk acquisition.
2. Processing.
3. Packaging.
4. Production Management.
5. Stock balancing.
6. Stock takes.
7. Time and Attendance authorising and capturing of leave.
52. Show commitment to the Food Safety management system.
53. Required to be an active team member of the Food Safety and HACCP team.
54. To participate in Food Safety and HACCP Meetings and Management Reviews.
55. To uphold all Food Safety policies and procedures and HACCP principles.
56. Attend training in relation to Food Safety.
57. To ensure:
1. Compliance of all staff to all Food Safety and HACCP policies and procedures.
2. Product traceability at all times.
3. Root Cause Analysis is conducted and implement Corrective Actions for food safety and CCP non-conformances.
4. All staff reporting to you attend food safety training.
5. Participate in 3rd Party audits conducted by:
1. SABS – Food Safety Management System Certification.
2. FSA on behalf of PnP and other Retailers.
3. QPro on behalf of Shell.
4. Adhoc supplier audits.
6. All employees to have job descriptions and key performance areas.
7. All employees Time and Attendance hours are verified and overtime authorised on D3.
8. Time sheets to be completed and signed off for all staff not on clocking system.
9. Employees leave to be monitored and planned for the year.
10. Comply at all times with the sick leave policy & leave policy.
11. All employees have performance reviews at least annually.
12. Ensure all disciplinary issues that relate to your department are dealt with including correctly corrective counselling and arranging disciplinary hearings with assistance of HR Manager.
13. Document and record all counselling and verbal warnings for future reference.
14. To be consistent and fair when disciplining staff.

Skills:

1. Strong leadership and team management abilities.
2. Excellent problem-solving and decision-making skills.
3. Ability to analyze production data and improve efficiency.
4. Strong understanding of lean manufacturing principles.
5. Effective communication and interpersonal skills.
6. Attention to detail and ability to maintain high-quality standards.
7. Ability to work under pressure and meet production deadlines.

Qualifications:

1. A degree or diploma in Production Management, Engineering, Industrial Management, Operations Management, or a related field.
2. Strong knowledge of health and safety regulations and quality control standards.
3. 5+ years of experience in a production, manufacturing, or operations management role.
4. Proven track record in leading production teams and optimizing processes.
5. Experience with inventory control, cost management, and workflow planning.
6. Strong understanding of machinery, equipment, and production technologies.
7. Hands-on experience with ERP systems and production scheduling software.