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UpMan Placements Private Limited
Factory Manager
UpMan Placements Private Limited · posted 4 months ago
Ghanaplant operations
About the role
Job Description
Factory Manager BLOWPAK INDUSTRIES LTD. Accra – Sheet Extrusion, Thermoforming & Injection Molding Operations
Department:
Production / Operations
Location:
[
Accra
]
Reports To:
Group
General Manager
/ MD
Company Overview
We are a growing manufacturing company operating advanced GPPS/HIPS and PP sheet extrusion, thermoforming, PP sheet, thermoforming , and injection molding production lines for packaging and disposable products. Our facility utilizes machinery from Sunwell Global, MEAF Machines, and RR Plast Extrusions.
We are looking for a highly proactive and result-oriented Factory Manager to lead production, maintenance, planning, quality, manpower coordination, and operational excellence across all plant divisions.
Position Summary
The Factory Manager will be responsible for complete factory operations related to sheet extrusion, thermoforming, PP sheet and thermoforming and injection molding divisions. The role includes production planning, manpower management, maintenance coordination, raw material planning, quality assurance, safety compliance, breakdown reduction, productivity improvement, and achievement of operational targets while maintaining high quality standards.
The candidate must ensure efficient utilization of machinery, manpower, materials, and resources to achieve production efficiency targets and customer delivery requirements.
Key Responsibilities
Production & Operations Management
- Manage complete factory operations for GPPS/HIPS and PP sheet extrusion, thermoforming, PP cup, and injection molding divisions.
- Ensure smooth operation of extrusion and thermoforming machines from Sunwell Global, MEAF Machines, and RR Plast Extrusions.
-
Oversee day-to-day activities of:
-
- Thermoforming Division (Sheet extrusion Sunwell/RR Plast Extrusion) and Sunwell Global Thermoforming for GPPS/HIPS Food packs.
- Sheet Extrusion Division (PP Sheet Extrusion Sunwell/RR Plast/MEAF)
- Injection Molding Division for GPPS/HIPS spoons, forks, and cutlery products.
-
- Plan and monitor daily, weekly, and monthly production schedules.
- Coordinate with the sales team to align production with customer demand and dispatch schedules.
- Ensure production targets are achieved with optimum machine utilization.
- Maintain overall line efficiency at minimum 90%.
- Drive continuous productivity improvements and process optimization.
Raw Material, Recipe & Consumption Control
- Plan and monitor raw material requirements including GPPS, HIPS, PP, additives, and reprocessed materials.
- Control usage of recycled/reprocessed material as per approved standards and process limits.
- Monitor and control masterbatch, additives, and other ingredient consumption as per approved recipes and formulations.
- Ensure proper batching and material handling procedures are followed.
- Control wastage, rejection, and excess material consumption.
- Ensure timely availability of packaging materials for finished goods dispatch.
- Coordinate with procurement and stores to avoid production interruptions.
Maintenance & Engineering Coordination
- Coordinate with maintenance and production teams for preventive and predictive maintenance activities.
- Reduce machine breakdowns through proactive maintenance planning.
- Monitor spare parts inventory and ensure critical spares availability for all machinery.
- Liaise with machinery suppliers and vendors for technical support, troubleshooting, upgrades, and spare procurement.
- Support installation, commissioning, and execution of new projects and modifications.
- Guide maintenance and production teams for continuous operational improvements.
Quality Management
- Ensure products meet internal and customer quality standards.
- Monitor process parameters and implement corrective actions to reduce rejection and wastage.
- Work closely with QA/QC teams to improve product consistency and process stability.
- Ensure recipe compliance and process discipline across all divisions.
- Drive continuous improvement initiatives for quality enhancement.
Manpower & HR Coordination
- Allocate manpower effectively across shifts and departments.
- Supervise production supervisors, engineers, operators, technicians, and shift personnel.
- Coordinate with the HR Manager regarding manpower planning, attendance, discipline, recruitment, shift management, and workforce-related matters.
- Conduct performance monitoring, training, and skill development for operational teams.
- Ensure discipline, teamwork, and operational accountability within the factory.
Safety & Compliance
- Ensure strict compliance with factory safety procedures and operational SOPs.
- Monitor machinery safety systems and workplace safety practices.
- Manage LPG stock control and safe handling procedures.
- Ensure compliance with fire safety, electrical safety, and machine safety standards.
- Promote a strong safety culture within the plant.
Reporting & Management Coordination
- Prepare and submit daily, weekly, and monthly operational reports to management.
- Analyze production data, downtime, efficiency, wastage, manpower utilization, and machine performance.
- Present action plans for operational improvements and cost reduction initiatives.
- Maintain proper documentation and reporting systems.
- Report directly to the Operational Manager / General Manager.
Key Performance Indicators (KPIs)
- Production target achievement
- Line efficiency ≥ 90%
- Breakdown reduction
- Rejection and wastage reduction
- Productivity improvement
- Raw material consumption control
- Recipe and process compliance
- On-time delivery performance
- Safety compliance
- Inventory and spare management effectiveness
Required Qualifications
- Bachelor’s Degree in Mechanical Engineering, Electrical Engineering, Polymer Engineering, Plastic Technology, Industrial Engineering, or related field.
- Candidates with Engineering or Plastic Technology background are preferred.
- Minimum 10 –15 years of experience in the plastic sheet extrusion, thermoforming, and injection molding industries.
- Candidates with experience in similar plastic packaging and disposable product industries will be preferred.
- Strong knowledge of GPPS/HIPS and PP processing.
- Experience handling thermoforming and injection molding operations , maintenance activities including utilities (Chiller/Air compressors)
- Hands-on experience with extrusion and thermoforming machinery.
- Strong leadership and problem-solving skills.
- Good knowledge of preventive maintenance systems and production planning.
- Strong communication and interpersonal skills are mandatory.
- Good computer knowledge and reporting skills for daily operational reporting to management.
- Proficiency in MS Excel, MS Word, production reporting, and operational data analysis.