Production Manager

Position: Production Manager –Maintenance & Production

Reports to: Chief Value Stream Leader

Location: Thika/Ruiru, Kenya

About our Client

Our client’s Beverages and Snacks is one of East Africa's fastest-growing FMCG manufacturers, operating a highly automated, digitally integrated plant in Nairobi, Kenya. The facility runs state-of-the-art Krones filling lines, KraussMaffei Injection and Netstal Caps injection moulding machines, and a full suite of PET-based beverage technologies including CSDs, Nitrogen Hot Fill Juices, Energy Drinks, and Water. The plant culture is built on precision, digital discipline, real-time reporting, and a relentless drive for operational excellence.

Key Responsibilities

1.  Production Operations and Line Management

•    Own end-to-end production operations across all PET beverage lines - Nitrogen Hot Fill Juice, CSDs, Energy Drinks, and Water filling lines.

•    Lead the production planning and scheduling process; manage RMPM (Raw Material & Packaging Material) projections to ensure optimised inventory levels and zero production stock-outs.

•    Set and enforce shift targets, 95%+ completion of the monthly production schedule on time and in full (OTIF) and line priorities in alignment with supply chain and dispatch requirements

•    Guarantee production efficiency above 85% OEE while maintaining total process wastage below 1%; ensure all Krones lines run with zero/minimal unplanned stoppages.

•    Material Reconciliation Accuracy: 100% accuracy in shift-end reconciliation between SAP and physical stock for preforms, caps, labels, and shrink film.

•    First-Pass Quality (FPQ): 99.5% of products meeting quality specs without rework or rejection.

•    Monitor Nitrogen dosing parameters, fill weights, dissolved oxygen, fill temperature, vacuum, torque, seaming/capping integrity, and labelling quality on Hot Fill PET juice lines - maintained within validated ranges at all times.

•    Drive a culture of line discipline - every line start, stoppage, speed change, quality event, and batch yield record must be logged in real time on the digital system.

•    Lead all line qualification, product changeover, and CIP/SIP activities to GMP and food safety standards.

•    Champion cost-saving initiatives, energy reduction programmes, weight reduction projects, and overhead optimisation to improve the plant's bottom line.

•    Oversee the organisational structure of the plant - performance management, skill development for technicians/operators, and shift allocation.

2. Plastic (PET Preforms &Cups) Manufacturing.

•    Oversee PET preform production on KraussMaffei injection moulding machines, ensuring IV integrity, wall uniformity, and gate quality are consistently within specification.

•    Manage HDPE/PP cap production on Netstal Synergy machines, maintaining dimensional compliance, torque performance, and tamper-evident band integrity.

•    Conduct or direct first-level troubleshooting on moulding machines - gate defects, flash, short shots, IV degradation, cycle time variation - without reliance on external OEM support for routine issues.

•    Monitor and review hot runner performance, melt temperature profiles, and cooling system efficiency across all moulding lines.

•    Oversee mould maintenance scheduling, cavity wear tracking, and spare parts readiness in collaboration with the Maintenance Lead.

3. Maintenance, Engineering and Technical oversight

·         MTTR (Mean Time To Repair): Reduce the average time taken to fix breakdowns to target levels (e.g., <30 minutes for minor automation faults). Track and continuously improve MTTR (Mean Time to Repair) and MTBF (Mean Time Between Failures) targets; target MTTR below 30 minutes for minor automation faults.

·         Direct the maintenance strategy for Krones, KraussMaffei, and Netstal lines; ensure shared utilities (HP/LP Air, Chillers, Power) are optimised for 24/7 operations.

·         Be the first point of technical escalation for all mechanical, electrical, automation, and pneumatic faults on filling and moulding lines - this is a hands-on, floor-present role.

·         Drive and review Preventive Maintenance (PM) and Predictive Maintenance (PdM) programmes across all assets; ensure 100% PM schedule adherence.

·         Liaise with internal teams and, where required, with Krones, KraussMaffei, and Netstal service teams for planned overhauls, software upgrades, and technical support.

4.   Financial & Cost Control KPIs

• Utility Specific Consumption: Reduce the cost of electricity/water per unit produced (e.g., kWh per 1,000 bottles) by 5–10%.
• Maintenance Spend vs. Budget: Oversee calibration, spare parts inventory, critical component lifecycle management, and vendor costs within +/-2% of annual maintenance budget.

• Inventory Turnover: Reduce "dead stock" in the inbound store by optimizing RMPM projections and lead times.

5.  Digital Systems, Reporting & Data Discipline

•    Champion a culture of real-time digital reporting - all production, quality, and maintenance data must be entered on time, every time, without exception.

•    Own daily, weekly, and monthly production KPI dashboards: OEE, line efficiency, downtime analysis, waste, scrap rates, yield, and RMPM reconciliation.

•    Ensure all shift reports, batch records, CIP logs, and quality certificates are completed accurately and submitted within the shift.

•    Drive utilisation of SAP (PP, MM, PM modules) and MES systems; enforce 100% material reconciliation accuracy and zero tolerance for retrospective or fabricated entries.

•    Use data proactively to identify trends, anticipate equipment failures, and implement corrective actions before problems escalate.

•    Cost-Saving Initiatives: Identify and implement at least two major Kaizen/digitization projects per year with a measurable ROI.

6.   Quality, Food Safety & Compliance

•    Ensure all products leaving the plant conform fully to internal specifications and regulatory requirements - target First-Pass Quality (FPQ) of 99.5%.

•    Enforce GMP, HACCP, ISO 22000, and FSSC 22000 compliance across all production and packaging areas.

•    Lead root cause analysis for all quality deviations using structured methodologies (5-Why, Fishbone); implement corrective and preventive actions.

•    Ensure in-process quality checks are conducted at defined frequencies by trained operators, with results captured digitally in real time.

•    Oversee raw material, packaging material, WIP, and finished goods inspection protocols, including laboratory coordination.

7.   People Leadership & Team Development

•    Manpower Productivity: Units produced per man-hour (UPMH) targets to ensure optimal labour utilization.

•    Skill Matrix Improvement: Conduct competency assessments and build training plans targeting 90% of operators/technicians at Level 3 (operate and troubleshoot independently) within 12 months.

•    Project Timelines: 100% on-time delivery of new development tasks and expansion projects.

•    Safety Record: Zero Lost Time Injuries (LTI) and 100% compliance with HSE protocols on the shop floor.

•    Lead, inspire, and develop a multi-disciplinary technical team of 50+ including Line Supervisors, Automation Lead, Mechanical & Electrical Engineers, Quality Controllers, Boiler and RO Operators, Machine Operators, and support staff.

•    Build a high-performance production culture through structured shift briefings, accountability reviews, and visible floor leadership.

•    Address performance gaps swiftly and constructively; recognise and reward discipline, initiative, and technical excellence.

•    Foster a safety-first mindset - enforce LOTO, PPE compliance, and safe work permit systems; maintain zero Lost Time Injuries (LTI).

•    Support recruitment, team retention, and motivation in collaboration with HR and relevant authorities.

8.   New Products, Projects & Continuous Improvement

•    Act as primary lead for new product development, facility expansions, and commissioning of new machinery - from R&D trials through to validated commercial production.

•    Prepare and review Technical Feasibility Analysis and Project Reports for capital expenditure proposals and plant expansion projects; ensure 100% on-time delivery.

•    Institutionalise Kaizen, 5S, SMED, and Lean manufacturing methodologies; deliver at least two major improvement projects per year with measurable ROI.

Identify and eliminate chronic losses using structured problem-solving and data-driven approaches

Candidate Profile-Qualification and Experience

Education & Background

•    Bachelor's Degree in Mechanical, Electrical, or Industrial Engineering (or closely related field).

•    An MBA or specialisation in Supply Chain / Operations Management is a significant advantage.

Experience Required

•    12-15+ years of total manufacturing experience, with a minimum of 5 years in a senior production leadership role in a Beverage and Plastics/Packaging plant.

•    Hands-on, proven experience operating and troubleshooting Krones filling and packaging lines (Contiform, Modulfill, Checkmat, Linajet, or equivalent).

•    Direct operational experience on KraussMaffei and/or Netstal injection moulding machines for PET preforms and closures.

•    Strong working knowledge of Nitrogen-based Hot Fill PET juice processing - dissolved oxygen control, fill temperature, nitrogen dosing, and vacuum integrity.

•    Advanced proficiency in SAP (PP, MM, PM modules) and production data analytics within an ERP/MES-driven plant environment.

Technical Competency

·         Deep knowledge of Krones Contiform, Modulfill, Checkmat, Linajet, and downstream automation. Ability to independently resolve line faults without OEM call-out.

·         Hands-on troubleshooting of KraussMaffei and Netstal machines - IV degradation, gate defects, flash, hot runner issues, cycle time anomalies.

·         Validated process knowledge of nitrogen dosing, fill temperature control, vacuum sealing, and dissolved oxygen management for PET juice lines.

·         Ability to read engineering drawings, diagnose hydraulic/pneumatic/electrical faults, and direct repair activities at component level.

·         Practical understanding of PLC-controlled systems, HMI interfaces, SCADA data interpretation, and alarm management on Krones and moulding machine platforms.

·         Advanced SAP (PP/MM/PM) and MES proficiency; real-time data entry culture; generation of meaningful KPI analysis from plant data.

·         HACCP, GMP, ISO 22000, FSSC 22000 - implementation, auditing, and deviation management.

·         Ability to lead, motivate, assess, and develop a diverse technical team of 50+ across multiple shifts and functions.

·         Material forecasting, long-term capacity planning, cost control, and proven ability to bridge technical engineering with commercial production goals.

·         Practical application of 5S, Kaizen, SMED, TPM, and root cause analysis in a high-speed FMCG environment.

Leadership and Behavioural Profile

The ideal candidate will demonstrate the following qualities consistently:

•    Visible, floor-present leader who earns respect through technical credibility, not only authority.

•    Highly disciplined in reporting and data accuracy - sets the standard personally before enforcing it with the team.

•    Calm under pressure; able to make fast, sound decisions during line breakdowns without causing panic or escalation.

•    Proactive and solutions-oriented - identifies problems before they escalate and acts without waiting to be asked.

•    High sense of ownership - treats the plant, its assets, and its output as a personal responsibility.

•    Strong communicator - equally effective engaging with floor operators, technical engineers, and senior management.

•    Resilient and adaptable in a fast-moving, high-growth FMCG manufacturing environment.

•    Change champion - proven track record of leading large teams through process digitalisation and operational transformation.