Plant Manager (Fertilizer Manufacturing)

1. Plant Operations & Production Management Lead and manage overall day-to-day fertilizer manufacturing operations. Ensure achievement of production targets, throughput, quality standards, and operational KPIs. Oversee manufacturing processes including: Raw material handling Precise dosing and powder blending Steam granulation Drying and cooling Screening and sizing Product conditioning and coating Packing and dispatch coordination Develop, implement, and continuously improve Standard Operating Procedures (SOPs). Ensure optimum utilization of manpower, machinery, raw materials, and utilities. Monitor production schedules and coordinate with planning and supply chain teams. 2. Fertilizer Manufacturing & Technical Expertise The candidate should have strong hands-on experience in manufacturing and process management of fertilizer products, including: NPK Grades: 19-19-19 17-17-17 15-15-15 14-35-14 14-28-14 12-32-16 NPS Grades: 19-38-0-7S 13.3-33.3-0-13.7S 12-42.2-0-10 Experience in different Coated Urea grades will be highly preferred. Strong understanding of fertilizer raw materials, nutrients, micronutrients, specifications, and properties. Knowledge of raw material compatibility and formulation requirements for different fertilizer SKUs. Strong understanding of Mass Balance and Heat Balance calculations. Ability to optimize formulations while maintaining product quality and production efficiency. 3. Process Control & Continuous Improvement Monitor key production KPIs including yield, efficiency, material consumption, recycle ratio, energy consumption, fuel usage, and downtime. Identify and troubleshoot process deviations and operational bottlenecks. Resolve issues related to: Granule size distribution Moisture control Steam optimization Binder optimization Caking prevention Product hardness Nutrient consistency Material losses Conduct root cause analysis for production failures and implement corrective actions. Drive continuous improvement initiatives such as: 5S Quality Circles Lean Manufacturing Process Optimization Waste Reduction Focus on improving plant productivity and reducing operational costs. 4. Quality Assurance & Product Compliance Work closely with QA/QC teams to ensure all products meet required specifications. Ensure consistency in: Nutrient composition Moisture content Granule size Physical hardness Product appearance Chemical specifications Ensure compliance with regulatory and customer quality standards. Monitor raw material quality and approve materials based on technical specifications. Implement corrective measures for non-conforming products. 5. EHS & Regulatory Compliance Ensure strict implementation of Environmental, Health, and Safety policies across the plant. Maintain compliance with local regulations and industry standards. Promote a strong safety culture among employees and contractors. Conduct hazard identification and risk assessments, including HAZOP/HAZID where applicable. Lead incident investigations and implement preventive measures. Ensure proper handling, storage, and usage of chemicals and raw materials. Drive continuous improvement in workplace safety and environmental performance. 6. Team Leadership & Development Lead and manage plant operations teams, including: Shift Supervisors Production Engineers Process Engineers Plant Operators Technical Staff Provide technical guidance, mentoring, and training to the operations team. Establish performance standards and monitor employee productivity. Conduct regular performance reviews and skill development initiatives. Build a disciplined, accountable, and safety-focused plant culture. Ensure effective manpower planning and shift management. 7. Maintenance & Reliability Coordination Coordinate closely with the Maintenance team to ensure high equipment reliability. Develop preventive and predictive maintenance plans. Minimize unplanned breakdowns and production downtime. Monitor the condition and performance of critical plant equipment. Support troubleshooting of mechanical and process-related issues. Participate in shutdown planning and major maintenance activities. 8. Production Planning & Supply Chain Coordination Coordinate with Supply Chain and Procurement teams to ensure timely availability of raw materials. Align production planning with sales forecasts and inventory requirements. Monitor raw material consumption and optimize inventory levels. Ensure efficient coordination between production, warehouse, packing, and dispatch teams. Support operational budgeting and cost control initiatives. 9. Reporting & Performance Management Prepare and present regular reports on: Production performance Plant efficiency Material consumption Energy consumption Downtime Quality performance Safety performance Operational costs Report operational risks, challenges, and improvement opportunities to senior management. Develop production forecasts and operational plans. Monitor budget performance and implement corrective actions where required.