Operation Manager

Industry: AI Textiles (Terry Towel Manufacturing Unit)

Position: Operations Manager

Position Summary:

The General Manager – Operations is responsible for the complete management of factory operations and acts as the operational representative of the Director. The position carries full responsibility for production planning, manufacturing operations, quality assurance, maintenance, compliance, inventory coordination, cost control, and cross-functional leadership. The incumbent shall ensure smooth execution of all manufacturing activities, optimize operational efficiency, achieve production targets, maintain export-quality standards, and ensure timely delivery while maximizing profitability and operational excellence.

Location: Khurrianwala, Faisalabad.

Key Objectives

• Achieve production targets within approved budgets.
• Ensure on-time delivery (OTD) of customer orders.
• Maintain world-class product quality.
• Optimize machine utilization and manufacturing efficiency.

* Reduce production costs and wastage.

* Ensure compliance with all legal and customer requirements.

* Drive continuous operational improvement.

Key Responsibilities

1. Production Planning & Operations Management

* Develop and implement the Master Production Schedule (MPS) based on sales forecasts and confirmed customer orders.

• Oversee the complete manufacturing process including:

o Terry Weaving

o Dyeing (Yarn & Piece)

o Cutting

o Stitching

o Finishing

o Packing

* Ensure effective production planning and capacity utilization across all departments.

* Monitor production progress and take corrective actions to meet delivery schedules. Optimize Labor productivity and machine efficiency.

* Ensure smooth coordination among all production units.

• Monitor production KPI’s and implement continuous improvement initiatives.
• Drive Lean Manufacturing throughout the plant.

2. Cost Control & Profitability

* Control manufacturing costs including:

o Direct Labor

o Utilities (Electricity, Gas & Water)

o Raw material consumption

o Production overheads

• Monitor production variances and recommend corrective actions. Reduce material wastage and improve process efficiency.
• Improve Overall Equipment Effectiveness (OEE).
• Support monthly profitability analysis through operational cost monitoring.

3. Quality Assurance

* Establish quality control checkpoints at each stage of production.

* Ensure compliance with customer specifications and export quality requirements.

• Maintain Acceptable Quality Level (AQL) standards.

* Investigate customer complaints and implement corrective and preventive actions (CAPA).

* Reduce rejection rates and rework through continuous improvement.

• Promote a culture of "Right First Time" manufacturing.

Establish quality control checkpoints at each stage of production.

* Ensure compliance with customer specifications and export quality requirements.

` Maintain Acceptable Quality Level (AQL) standards.

* Investigate customer complaints and implement corrective and preventive actions (CAPA).

* Reduce rejection rates and rework through continuous improvement.

4. Cross-Functional Coordination

Export / Marketing

* Coordinate production priorities according to shipment schedules.

• Ensure sampling and bulk production meet customer specifications.
• Monitor order status and delivery commitments.

Purchase Department

* Coordinate procurement planning for:

o Yarn o Dyes

o Chemicals

o Accessories

o Packaging Materials

* Prevent production interruptions due to material shortages.

• Maintain optimum inventory levels.

HR & Administration

• Plan manpower requirements.
• Monitor attendance, discipline, and workforce productivity.
• Support recruitment, training, and employee development.
• Ensure compliance with company policies and Labor regulations

5. Maintenance & Engineering

* Ensure preventive and predictive maintenance of:

o Looms

o Dyeing Machines

o Stitching Machines

o Utility Equipment

• Minimize equipment downtime.
• Improve machine reliability and operational efficiency.
• Monitor maintenance KPIs and equipment performance.

6. Inventory & Material Management

• Monitor inventory levels of raw materials, work-in-process (WIP), and finished goods.
• Ensure inventory accuracy.
• Reduce inventory losses and wastage.
• Coordinate stock verification activities with Stores and Accounts.

7. Performance Reporting Prepare and present

• Daily Production Reports
• Weekly Operations Reports
• Monthly Plant Performance Dashboard
• Production Efficiency Reports
• Quality Reports Cost Analysis Reports
• Downtime Analysis
• Capacity Utilization Reports

* Wastage Analysis

• Inventory Status Reports

Present findings and recommendations to the Director for strategic decision-making.

Qualifications

Bachelor's Degree in Textile Engineering, Industrial Engineering, Manufacturing Engineering, or Industrial Management.

• MBA or equivalent management qualification will be preferred.

Experience

5–10+ years of progressive experience in Home Textile or Terry Towel manufacturing.

• Minimum 3 years in a senior management role.
• Experience in export-oriented manufacturing is mandatory.

Pay: Rs250,000.00 - Rs500,000.00 per month

Work Location: In person