Production Manager - Refinery

Responsibilities Production Management * Manage the day-to-day operation of the edible oil refinery to achieve agreed production volumes, quality specifications and cost targets. * Develop and implement production plans in line with raw material availability, customer requirements and business objectives. Ensure efficient operation of all refining processes, including: * Degumming * Neutralization / chemical refining * Washing * Drying * Bleaching * Filtration * Deodorization * Final oil handling and storage * Monitor plant performance, production rates, downtime and process efficiency. * Identify and eliminate production bottlenecks and operational losses. * Ensure effective shift management, production discipline and adherence to standard operating procedures. * Drive continuous improvement in plant utilization and overall equipment effectiveness. Canola Oil – Chemical Refining * Provide technical and operational leadership in the chemical refining of canola oil. * Optimize caustic dosing, acid conditioning, separation, washing and drying processes to achieve maximum oil recovery and consistent quality. * Monitor the effect of raw-material quality on refining performance and yield. * Control soap stock, neutral oil losses and other process losses. * Optimize operating parameters to achieve the required FFA, moisture, phosphorus, colour and other product specifications. * Identify opportunities to improve refining efficiency, while maintaining product quality and food safety. Yield and Oil Loss Control * Take overall responsibility for oil yield and process-loss management. * Establish and monitor yield targets for the refinery. * Analyze daily and monthly oil balances and investigate deviations from expected yield. * Identify sources of neutral oil loss throughout the refining process. * Monitor losses through soap stock, wash water, filtration, bleaching earth, deodorization and process drainage. * Implement corrective actions to reduce oil losses and improve overall recovery. * Develop reliable production and mass-balance reporting systems. Maintenance Management * Work closely with the Maintenance Manager to ensure maximum plant availability and reliability. * Develop and implement effective preventative and planned maintenance programmes. * Identify critical equipment and establish appropriate maintenance strategies. * Monitor breakdowns, recurring failures and equipment-related production losses. * Participate in root-cause analysis of major equipment failures. * Ensure maintenance activities are properly planned around production requirements. * Support the identification and replacement of obsolete, unreliable or undersized equipment. * Ensure critical spares and replacement components are identified and available. * Monitor maintenance-related downtime and drive continuous reduction in unplanned stoppages. Capacity Improvement and Plant Optimization * Identify opportunities to increase refinery throughput and improve plant utilization. * Lead or support projects aimed at increasing production capacity. * Identify process bottlenecks and develop practical engineering solutions. * Optimize equipment utilization, process flow, residence times and operating parameters. * Evaluate debottlenecking opportunities involving pumps, heat exchangers, boilers, separators, filters, vacuum systems and other critical refinery equipment. * Participate in capital projects, equipment upgrades and process modifications. * Measure and report on the production benefits achieved from improvement projects. * Drive continuous improvement in plant efficiency, energy consumption and operating costs. Quality Management * Ensure all refined oil produced meets defined customer, company and statutory quality specifications. * Work closely with the Quality Assurance department to maintain consistent product quality. * Monitor critical quality parameters throughout the refining process. * Ensure effective process controls are in place to prevent quality deviations. * Investigate production-related quality complaints and implement corrective and preventative actions. * Maintain process discipline and ensure operators understand the relationship between operating conditions and final product quality. * Promote a strong quality-at-source culture throughout the production department. FSSC 22000 and ISO Compliance * Ensure production activities comply with FSSC 22000, ISO and applicable food-safety and quality-management requirements. * Maintain compliance with documented procedures, work instructions and operational controls. * Ensure effective implementation of HACCP and relevant prerequisite programs within the production environment. * Participate in internal and external audits. * Ensure audit findings and non-conformances are addressed within agreed timeframes. * Maintain accurate production records and traceability documentation. * Promote food safety, hygiene, allergen control, contamination prevention and good manufacturing practices. * Ensure employees receive appropriate training in food safety, quality and operational requirements. Health, Safety and Environmental Management * Ensure production activities are conducted in accordance with company SHEQ policies and statutory requirements. * Promote a strong safety culture throughout the refinery. * Ensure operators follow safe operating procedures, permit systems and lock-out/tag-out requirements. * Investigate incidents and near misses and implement corrective actions. * Control chemical handling risks associated with caustic soda, acids, bleaching earth and other refinery chemicals. * Monitor environmental impacts, including effluent, waste, emissions and chemical losses. People Management * Lead, motivate and develop the production team. * Set clear performance expectations and monitor individual and team performance. * Ensure operators are appropriately trained and competent. * Identify training and development requirements. * Promote accountability, discipline and effective communication. * Develop a culture of continuous improvement and problem solving. * Ensure effective communication between shifts and departments. Performance Monitoring and Reporting Maintain and report key production performance indicators, including: * Production volume – tons/day and tons/month * Refinery capacity utilization * Oil yield and recovery * Neutral oil losses * Soap stock losses * Downtime and production availability * OEE * Product quality compliance * Chemical consumption * Bleaching earth consumption * Energy consumption * Maintenance-related downtime * Production cost per ton * Waste and effluent generation * Customer quality complaints * Prepare regular production reports for management and provide recommendations for improving plant performance. Health and Safety * Participate in safety forums and attend relevant training/programmes * Report all safety incidents to the relevant people * Comply with safety policies and procedures * Wear protective clothing (where applicable) at all times Employee management and development * Ensure overall compliance to relevant procedures and policies * Ensure that all team members have clearly defined job profiles * Regular goal reviews are completed to assess achievement of results * Support, coaching and mentoring is continuously provided to ensure that objectives are met * Appropriate allocation of resources to meet operational demands * Ensure adequate succession planning to meet ongoing and anticipated business requirements Requirements Qualification and Experience * Relevant tertiary qualifications inEdible oil refining, Food Technology, Production Management, or a related discipline. * Minimum 5–10 years' experience in edible oil processing/refining, preferably in a management or senior supervisory position. * Proven experience in chemical refining of canola oil. * Strong understanding of edible oil refining processes and process chemistry. * Demonstrated experience in oil yield optimization and loss control. * Experience managing refinery maintenance and equipment reliability. * Proven track record in capacity improvement and process optimization. * Experience working within FSSC 22000 and ISO-certified food manufacturing environments. * Working knowledge of HACCP, GMP and food-safety management systems. * Strong understanding of production planning, KPI management and cost control. Technical Competencies The candidate should demonstrate strong knowledge of: * Canola oil chemical refining * Degumming and neutralization * Caustic and acid dosing * Soap stock management * Oil washing and drying * Bleaching and filtration * Deodorization * Vacuum systems * Heat-exchange systems * Oil yield and mass balances * Process-loss identification * Preventative maintenance * Root-cause analysis * Process optimization * Production planning * Food safety and quality systems * FSSC 22000 / ISO standards * Continuous improvement methodologies Personal Competencies * Strong operational leadership * Analytical and problem-solving ability * Results-oriented approach * High level of attention to detail * Strong communication skills * Ability to work under production pressure * Commercial awareness * Strong safety and food-safety mindset * Ability to lead multidisciplinary teams * Strong planning and organizational skills * Ability to identify and implement practical improvements * High level of accountability and ownership Overall Accountability * The Production Manager is ultimately responsible for ensuring that the refinery operates safely, reliably and efficiently, producing the required volume of specification-compliant refined canola oil while maximizing yield, minimizing losses, controlling operating costs and continuously improving plant capacity and performance.