Factory Controller

SUMMARY:
Factory Controller

POSITION INFO:

The Factory Controller will be responsible for managing the day-to-day operations of the George chemical manufacturing plant, including basic warehouse and distribution activities, from raw material receipt to dispatch of finished goods. This role also incorporates responsibility for the Quality Control function, health and safety compliance, and production planning.

Production Management

• Oversee and supervise manufacturing operations to align with production schedules and quality standards.
• Manage product batch preparation, manufacturing, sampling, testing, adjustment, packing, and labelling in accordance with SOPs and Manufacturing Orders (MOs).
• Conduct product sampling, testing and adjust where necessary.
• Ensure effective inventory management, focusing on FIFO, shelf-life, proper labelling, traceability, and hazardous materials handling.
• Implement process improvements to optimise productivity and efficiency.
• Investigate production issues and manage incident reports, ensuring corrective actions are taken.
• Supervise staff, subcontractors, and vendors in daily operations.
• Ensure that blending operations are conducted safely and that all operators are medically cleared and trained.
• Maintain plant equipment and facilities, ensuring all resources are in good working order and PPE compliance is upheld.
• Track returnable raw material packaging by supplier.

Production Planning & Coordination

• Perform weekly stock takes of finished goods and develop a 4-week production plan and Materials Requirement Plan (MRP).
• Coordinate the handling and storage of raw and packaging materials after receipt and approval.
• Allocate human resources to ensure optimal productivity.
• Identify and implement opportunities for production improvements.

Procurement & Finance Management

• Oversee raw material procurement, supplier relations, price negotiations, and contract management where necessary.
• Monitor stock levels and place orders for raw materials, packaging, and spare parts.
• Manage production records in systems like Pastel, ensuring accurate data entry for stock and materials usage.
• Generate Purchase Orders (PO) and receive supplier invoices for raw and packaging materials.
• Capture finished goods into the system
• Utilise sales figures and generate weekly production plan, know Materials Requirement Plan (MRP)
• Control stock, report on losses, manage slow-moving inventory, and ensure timely updates to relevant systems.
• Keep financial oversight, ensuring alignment with production targets and budgets.

Health, Safety & Compliance

• Ensure full compliance with Health and Safety regulations and company standards.
• Promote a Zero Tolerance culture for PPE adherence and maintain safety protocols.
• Conduct daily warehouse inspections for potential risks or safety hazards.
• Report all incidents, accidents, or near misses promptly to management.
• Ensure staff have the appropriate training and certifications for handling hazardous materials and machinery.
• Maintain and update HSE files, ensuring records of inspections, incidents, and compliance are accurate.
• Management of effluent treatment processes – testing, treatment and release of factory effluent.
• Ensure regulatory compliance with bodies like SABS and NRCS.
• Act as the company representative during audits and liaise with regulatory bodies.
• Maintaining of Quality Management System (QMS) and associated documentation.
• Planning and conducting internal audits where necessary.

Quality Control & Laboratory

• Oversee the testing and approval of raw materials, in-progress work, and finished products.
• Maintain Certificates of Analysis (COAs) and manage retention samples.
• Assist with product development and non-conformance investigations.
• Ensure all laboratory and factory equipment is calibrated, serviced, and maintained.
• Purchasing of laboratory chemicals and consumables where necessary.

Administrative & Reporting

• Prepare and present reports on production performance metrics and project statuses.
• Attend departmental meetings and contribute to discussions.

Human Resources Management

• Assist HR in preparing/maintaining job descriptions for all direct reports where required.
• Ensure effective and regular meetings are held with direct reporting staff.
• Conduct regular performance reviews and ensure disciplinary standards are upheld.
• Ensure staff are trained, maintain company image, and present professionally.
• Supervise and manage the performance of approximately five production staff members, providing ongoing training and development.
• Manage time and attendance.
• Ensure staff medicals are completed and update to date at all times.
• Ensure all staff presents in a neat and professional manner with Company Branded Clothing and PPE.

Requirements:

• Matric certificate, preferably with a post-matric qualification in production management or a related discipline.
• 3-5 years of supervisory experience in a production management role within the chemical industry is essential.
• Strong knowledge of production concepts, health and safety regulations, and manufacturing processes.
• A dynamic individual who can effectively balance management with hands-on administrative responsibilities.
• Understanding of manufacturing and procurement / supply chain processes.
• Basic financial understanding will be advantageous.
• Competent in problem solving, team building, planning and decision making.
• Understanding of ISO and other systems.
• Attended to various production/quality audits.
• Valid Driver’s License and own reliable transport.
• Intermediate to advance Excel skills will be beneficial to this position.
• Exposure to Pastel / Syspro will be added advantageous.