Manufacturing Operations Specialist; cosmetics

Position: Manufacturing Operations Specialist (cosmetics)
Job Description – General Manager – Operations (Cosmetics & Personal Care Manufacturing)
Position Summary
The General Manager – Operations will lead the overall manufacturing operations of a cosmetics and personal care manufacturing facility, ensuring safe, efficient, GMP-compliant, and cost-effective production. The role will oversee Production, Filling & Packing, Quality, Engineering, Maintenance, Warehouse, Planning, Procurement Coordination, and EHS while driving operational excellence, productivity, and continuous improvement.

Key Responsibilities
Plant Operations
Lead end-to-end plant operations, including manufacturing, filling, packaging, engineering, maintenance, warehouse, and dispatch.
Ensure achievement of production plans while maintaining quality, safety, and regulatory compliance.
Improve plant productivity, capacity utilization, and Overall Equipment Effectiveness (OEE).
Optimize manpower and machine utilization to maximize operational efficiency.
Production Management
Oversee manufacturing of creams, lotions, shampoos, conditioners, serums, oils, face wash, body wash, gels, deodorants, perfumes, and other personal care products.
Ensure adherence to batch manufacturing records (BMR) and standard operating procedures (SOPs).
Coordinate production planning to achieve delivery commitments.
Minimize changeover time and production losses.
Filling & Packaging Operations
Manage filling, labeling, coding, sealing, cartoning, and secondary packaging operations.
Improve line efficiency and packaging productivity.
Reduce packaging material wastage and optimize packaging costs.
Quality & Regulatory Compliance
Ensure compliance with GMP, ISO 9001, ISO 22716 (Cosmetic GMP), and applicable regulatory requirements.
Work closely with QA/QC to reduce deviations, rejections, and customer complaints.
Ensure successful completion of customer and regulatory audits.
Engineering & Maintenance
Develop preventive and predictive maintenance programs.
Improve equipment reliability and minimize downtime.
Lead automation, debottlenecking, and plant expansion projects.
Monitor utilities including boilers, compressors, HVAC, purified water systems, and ETP/STP.
Supply Chain Coordination
Coordinate with Procurement for timely availability of raw materials and packaging materials.
Ensure inventory optimization without affecting production continuity.
Work closely with Planning, Sales, and Logistics for timely dispatches.
Cost Optimization
Prepare and manage annual operating budgets.
Drive initiatives to reduce manufacturing costs, energy consumption, and wastage.
Improve material yield and reduce batch losses.
Safety & Environment
Ensure compliance with EHS policies and statutory regulations.
Promote a zero-accident culture through regular safety audits and training.
Ensure proper waste management and environmental compliance.
Continuous Improvement
Implement Lean Manufacturing, TPM, Six Sigma, Kaizen, and 5S initiatives.
Lead productivity improvement and operational excellence projects.
Monitor KPIs and implement corrective actions to achieve operational targets.
Team Leadership
Lead and mentor Production, QA, QC, Maintenance, Engineering, Warehouse, and Planning teams.
Build a high-performance culture through coaching, performance management, and employee development.
Drive employee engagement and succession planning.
Key Performance Indicators (KPIs)
Production target achievement
OEE improvement
Capacity utilization
Manufacturing cost reduction
Batch Right First Time (RFT)
Rejection and scrap reduction
Customer complaint reduction
On-time delivery
Equipment uptime
Energy consumption reduction
Inventory accuracy
Safety performance (Zero Lost Time Incidents)
Qualifications
Bachelor's Degree in Chemical Engineering, Mechanical Engineering, Production Engineering, Industrial Engineering, Pharmacy, Cosmetic Technology, or a related discipline.
MBA in Operations or Manufacturing is preferred.
Experience
20 –25 years of experience in cosmetics, personal care, FMCG, skincare, haircare, toiletries, or beauty product manufacturing.
Minimum 5 years in a Plant Head, Operations Head, Factory Manager, or General Manager – Operations role.
Required Skills
Plant Operations Management
Cosmetic Manufacturing Processes
GMP & ISO 22716
Production Planning & Control
Filling & Packaging Operations
Lean Manufacturing
TPM
Six Sigma
Kaizen & 5S
Cost Control & Budgeting
SAP/ERP
Inventory Management
Preventive Maintenance
Quality Systems
Team Leadership
Continuous Improvement
CAPEX & Project Management
Preferred Industry
Cosmetics
Personal Care
Skin Care
Hair Care
Toiletries
Beauty Products
Contract Manufacturing (Third-Party Manufacturing)