Operations Manager – Flexible Packaging Conversion Plant

Accra, Ghana

Sintex Packaging Products Ghana - A fast-growing, flexible-packaging manufacturer in Accra serving West-African market. Our plant operates 24/7 and is equipped with 8-colour rotogravure printing presses, solvent-based & solvent-less laminators (duplex, triplex, 4-ply), PVC gluing lines, and high-speed turret slitters.

Position Summary

The Operations Manager is the single point of accountability for all converting processes—printing, lamination (solvent-based & solvent-less up to 4-ply), PVC gluing, and slitting—across two shifts and ±100 employees. You will drive safety, quality, cost, delivery, and continuous-improvement performance while ensuring full compliance with Ghana EPA, FDA-Ghana, and customer-specific standards.

Key Duties & Responsibilities

• Schedule rotogravure printing, multi-ply lamination, Shrink Sleeve, and slitting to maximize OEE, minimize changeover and achieve on-time delivery.
• Own daily KPI dashboard.
• Develop and maintain SOPs for gravure doctor-blade settings, anilox inventory, adhesive mix ratios (solvent & solvent-less), and slitting knife-planning.
• Ensure every lot meets customer specs (bond strength, residual solvent, WVTR/OTR, COF) and passes Ghana Standard Authority standards.
• Chair daily quality stand-up; approve holds, CAPA, and customer complaint investigations (target closure ≤ 7 days).
• Manage Ghana EPA VOC permits and solvent-recovery system; ensure hazardous-waste manifests are filed monthly.
• Drive a “zero-harm” culture; enforce LOTO, confined-space, hot-work, PPE, and combustible-dust programs compliant with Ghana Factories, Offices & Shops Act.
• Conduct at least two layered-process audits per week; lead monthly safety committee meetings.
• Lead Lean/6σ events (Kaizen, SMED, 5S) targeting ≥ 8% waste reduction and 10% speed increase YoY.
• Prepare and manage CAPEX proposals (new press, laminator upgrade, turret slitter, inline 100% inspection) with payback ≤ 24 months.
• Directly supervise Shift Supervisors, Process Engineers, Maintenance Superintendent, and Warehouse Lead; indirectly lead 100+ machine operators, QC technicians, and helpers across two shifts.
• Build training matrices for gravure set-up, solvent-less adhesive mixing, 4-ply lamination recipe management, PVC application, and slitting defect recognition.
• Conduct quarterly performance reviews and maintain succession pipeline for critical roles.
• Control raw-material usage variance (film, ink, solvent, adhesive) within ±1% of standard.
• Prepare weekly operations report for Plant Manager.
• Host technical audits and on-site trials; liaise with global ink, adhesive, and substrate suppliers on new product development.

Qualifications

• Bachelor’s degree in Engineering (Mechanical, Chemical, or Printing/Packaging) preferred; HND plus proven track record accepted.
• 10+ years’ flexible-packaging experience, including 5+ years managing rotogravure printing and solvent/solvent-less lamination in Africa or a comparable emerging market.
• Hands-on expertise with 4-ply structures, PVC cold-seal, and high-speed slitting; familiarity with Nordmeccanica, Kohli, or equivalent assets.
• Black Belt or Lean certification is highly desirable.
• Experience with ISO 9001, FSSC 22000, and customer audits strongly preferred.
• Proficiency with MS Excel.

Competencies

• Decisive, hands-on leader with high mechanical aptitude and resilience in a 24/7 environment.
• Strong cross-functional communicator (English fluency required).
• Cultural sensitivity to manage a diverse Indian/Ghanaian workforce.

Reporting Structure

Reports to: Plant Manager

Compensation & Benefits

• Competitive expatriate or local package (housing, school, medical, relocation support) commensurate with experience.
• Annual performance bonus tied to plant KPIs.

Travel

<10% regional travel for supplier/customer visits.

Equal Opportunity

We are an equal-opportunity employer committed to building a diverse and inclusive team in Ghana.