Production & Maintenance Manager

1. Job Purpose

The Operations Manager is responsible for the overall management, coordination, and performance of the EPS manufacturing plant in SHJ and Abu Dhabi. The role oversees Hot Production, Cold Production, Logistics, Stores, and Quality Departments, ensuring optimal productivity, manpower utilization, product quality, safety compliance, and cost control.

2. Departmental Structure Under Operations:

A. Hot Production Department

(Expansion, Block Molding, Shape Molding, Recycling)

Scope of Responsibility

The Hot Production Department covers all steam-based and primary foam processing operations including:

• EPS Pre-Expansion
• Block Molding
• Shape Molding
• EPS Recycling (Regrinding, Reprocessing and waste lumping)

Key Responsibilities

• Ensure accurate density control during pre-expansion.
• Monitor steam pressure, cycle times, and production efficiency.
• Achieve block molding output targets with minimal rejection.
• Supervise shape molding operations for customized molded products.
• Oversee recycling process to minimize raw material waste.
• Optimize bead aging and storage conditions.
• Reduce scrap rate and improve material yield.
• Coordinate closely with maintenance for steam and boiler reliability.
• Ensure proper machine parameter settings to avoid density variation.
• Implement strict safety procedures for steam and pressure systems.

Manpower & Training – Hot Production

• Determine optimal staffing per shift.
• Train operators on:
• Steam system safety
• Density control techniques
• Mold setup and changeover
• Waste reduction practices
• Develop multi-skilled operators.
• Monitor productivity per operator per shift.
• Reduce overtime through better workforce planning.

B. Cold Production Department

(Sheet Cutting, CNC Cutting, Special Cutting, Board Production)

Scope of Responsibility

The Cold Production Department covers all secondary processing and finishing operations including:

• Sheet Cutting Lines
• CNC Cutting Machines
• Special Profile Cutting
• Insulation Board Production and Packaging

Key Responsibilities

• Optimize block-to-sheet yield during cutting.
• Supervise CNC programming and nesting efficiency.
• Ensure dimensional accuracy and tolerance compliance.
• Manage special cutting orders and customized profiles.
• Oversee board production finishing and packaging.
• Reduce waste cutting and improve recovery rate.
• Ensure smooth workflow from Hot Production output to cutting lines.
• Maintain proper finished goods identification and labeling.

Manpower & Training – Cold Production

• Allocate workforce based on daily production schedule.
• Train operators on:
• Cutting optimization
• CNC programming efficiency
• Board quality standards
• Safe machine operation
• Develop skill matrix for cutting and CNC operators.
• Improve labor productivity (m³ per worker per shift).
• Minimize handling damage and material losses.

C. Quality Department Oversight

• Supervise Quality Control and Quality Assurance activities.
• Ensure compliance with ASTM, EN, and UAE Civil Defense standards.
• Monitor:
• Density consistency
• Compression strength
• Dimensional accuracy
• Fire-retardant compliance
• Implement corrective and preventive actions.
• Reduce internal rejection and customer complaints.

D. Logistics & Stores Management

• Supervise raw material warehouse (EPS beads, additives, packaging).
• Ensure FIFO system implementation.
• Control finished goods inventory.
• Plan dispatch schedules for on-time delivery.
• Monitor stock levels and minimize slow-moving inventory.
• Ensure accurate ERP inventory transactions.

3. Operational Excellence & Cost Control

• Monitor production cost per cubic meter.
• Control steam, electricity, and raw material consumption.
• Improve overall plant efficiency.
• Implement lean manufacturing practices.
• Lead continuous improvement initiatives.

4. Workforce Planning & Optimization

• Plan manpower requirements for 3-shift operations.
• Optimize labor distribution between Hot and Cold Departments.
• Reduce unnecessary labor redundancy.
• Establish clear KPIs for supervisors and operators.
• Conduct periodic performance evaluations.
• Develop succession planning for key technical roles.

5. Health, Safety & Environment (HSE)

• Ensure compliance with Abu Dhabi, Sharjah and UAE safety regulations.
• Oversee boiler and pressure vessel safety.
• Maintain fire prevention systems.
• Conduct safety training and drills.
• Enforce PPE compliance across departments.

6. Reporting & Performance Monitoring

The Operations Manager shall monitor and report on:

• Monthly production volume (m³)
• Yield percentage
• Waste ratio
• Labor productivity
• Machine uptime
• On-time delivery rate
• Inventory turnover
• Cost per m³
• Customer complaint rate

7. Qualifications

• Bachelor’s degree in mechanical, Industrial, or Production Engineering.
• 8–12 years of experience in EPS manufacturing.
• Minimum 5 years in senior operations or plant management role.
• Strong knowledge of steam-based EPS systems.
• Experience managing CNC and cutting operations.
• ERP experience (SAP Business One preferred).

8. Core Competencies

• Leadership and team management
• Manpower optimization
• Worker training and development
• Production planning and scheduling
• Cost control and budgeting
• Quality systems management
• Process improvement and efficiency optimization

Job Type: Full-time

Ability to commute/relocate:

• Abu Dhabi: Reliably commute or planning to relocate before starting work (Required)

Education:

• Diploma (Preferred)

Work Location: In person