Plant Operations Head

Job Description (JD) – Plant Head

Position: Plant Head 
Department: Manufacturing Operations 
Reporting To: Director – Manufacturing 
Location: Kolkata, Egypt
Industry: FMCG / Cosmetics & Personal Care

About the Role

We are seeking an experienced Plant Head to lead end-to-end manufacturing operations for a state-of-the-art cosmetics and personal care manufacturing facility. The ideal candidate will be responsible for production, quality, engineering, maintenance, EHS, supply chain coordination, regulatory compliance, cost optimization, and people management while ensuring adherence to international cosmetic manufacturing standards.

Key Responsibilities

Manufacturing Operations

• Lead daily plant operations to achieve production, quality, and efficiency targets.
• Ensure compliance with GMP, ISO 22716, and hygiene standards.
• Drive operational excellence initiatives such as TPM, Lean Manufacturing, Kaizen, 5S, and Six Sigma.
• Improve productivity, yield, and overall equipment effectiveness (OEE).

Quality & Regulatory Compliance

• Ensure compliance with local and international cosmetic regulations.
• Coordinate with Quality and Regulatory teams for audits, certifications, and inspections.
• Maintain complete traceability and documentation readiness.
• Drive a culture of quality and hygiene excellence.

Engineering & Maintenance

• Manage preventive and predictive maintenance programs.
• Ensure uninterrupted utilities including HVAC, compressed air, chilled water, and clean-room systems.
• Lead automation, energy optimization, and digital transformation initiatives.

Supply Chain & Inventory Management

• Collaborate with Procurement, Planning, and Logistics teams.
• Ensure availability of raw materials and packaging materials.
• Monitor warehouse operations, inventory control, and FIFO practices.
• Support export/import and dispatch activities.

EHS & Statutory Compliance

• Ensure compliance with safety, environmental, and labor regulations.
• Conduct risk assessments, safety audits, and emergency preparedness drills.
• Drive workplace safety and environmental sustainability programs.

Team Leadership

• Lead and mentor production, engineering, quality, warehouse, and support teams.
• Develop succession planning and capability-building programs.
• Foster a high-performance and collaborative work culture.

Cost & Performance Management

• Own plant-level cost management and operational budgets.
• Monitor KPIs including OEE, Yield, Downtime, OTIF, Safety, Scrap, and Absenteeism.
• Implement cost-saving initiatives while maintaining quality standards.

Project Management

• Support new product launches and plant expansion projects.
• Ensure timely installation, commissioning, and validation of new equipment.

Qualification & Experience

• B.E./B.Tech in Mechanical, Chemical, Production Engineering, or related discipline.
• MBA preferred.
• Minimum 20 years of manufacturing experience in FMCG/Cosmetics.
• At least 10 years in senior plant leadership roles.
• Strong experience in cosmetics and personal care manufacturing (creams, lotions, body washes, and formulations).

Key Skills

• Plant Operations Management
• GMP & ISO 22716 Compliance
• Lean Manufacturing & Six Sigma
• Production Planning & Control
• Engineering & Maintenance
• EHS Management
• Cost Optimization
• Team Leadership
• Supply Chain Coordination
• Project Management

About the Company: 

The company is a Kolkata-based FMCG contract manufacturer with global operations, including a major new plant in Egypt. It specializes in personal care, home care, and food products, serving leading international brands with over 28 years of expertise.  

Company Overview: 

Headquarters: Jalan Industrial Complex, NH-6, Biprannapara, Howrah, West Bengal, India 

Founded: 19 February 1996 

Status: Active Private Limited Company 

Revenue (FY 2025): ₹406 Crore 

Employees: ~164 (as of Feb 2025) 

Industry: FMCG Contract Manufacturing (Personal Care, Home Care, Food) 

🌍 Global Presence 

India (Kolkata): Two adjacent manufacturing units ok

Combined annual capacity: 130,000 tonnes 

Product categories: shampoos, handwashes, detergents, dishwashing bars, home care liquids, olive oils 

Egypt (Al Sokhna-Suez): 

Plant size: 50,000 sqm (Phase I: 18,000 sqm) 

Commissioned: October 2024, fully operational by Q1 2025 

Annual capacity: 50,000 MT 

Focus: shampoos, conditioners, creams, lotions 

Target markets: North America, Europe, Africa, UK 

🏭 Industry & Operations 

Sector: FMCG contract manufacturing 

Core Services: 

Product formulation 

Packaging design 

Quality control 

Pilot plants & stability chambers for R&D 

Capabilities: 

Original Design Manufacturing (ODM) 

Private Label Manufacturing 

Contract Manufacturing (end-to-end solutions) 

R&D facilities with pilot plants and stability chambers 

Production Scale: Over 200,000 tonnes annually, 300+ SKUs 

Clients: 15+ global FMCG brands 

Global Clients: 250+  

📌 Key Notes 

Egypt's plant was completed in 10 months (Dec 2023 – Oct 2024), highlighting rapid execution. 

Exports from Egypt facility reach multiple international markets. 

Strategic location in SCZone provides efficient access to global ports for distribution