Production Supervisor

The IRCA Group is an International Leader in high quality finished and semi-finished ingredients for the bakery, pastry, and ice cream markets. With a solid history of over 100 years in the industry, the Group has its headquarters in Italy (Gallarate) and a strong global footprint with 23 production sites and over 2,000 employees in Europe, the United States, and Vietnam.

Our core product categories include chocolate, compounds, chocolate decorations, sprinkles, creams, pastry mixes, gelato ingredients, nuts, and candied fruit. The most recent acquisition of Kerry Sweet complements our existing categories with the addition of sweet particulates, chocolate confections, inclusions, variegates, and frozen fruit purees.

Through its 8 key brands (IRCA, Dobla®, in2food, Via Degli Orsini, JoyGelato, RaviFruit, Cesarin, and Anastasi®), the IRCA Group offers an unparalleled "one-stop shop" approach for delivering quality solutions to all ingredients needs, through a broad range of innovative products. We offer everyday & seasonal solutions to 3 macro channels: Gourmet, Food Manufacturing, and Consumer Product (Retail). “Extraordinary made simple.”

We are currently seeking a Production Supervisor responsible for overseeing manufacturing operations while ensuring compliance with safety, quality, food safety, and operational standards. This role provides frontline leadership to production teams during the night shift, ensuring efficient production flow, staffing coordination, and timely resolution of operational issues in a fast-paced manufacturing environment.

The ideal candidate has a strong manufacturing and technical background, hands-on problem-solving skills, and the ability to lead teams effectively during off-shift operations. This position works closely with Production, Maintenance, Quality, and Engineering teams to maximize efficiency, reduce downtime, maintain product quality, and support continuous improvement initiatives.

RESPONSIBILITIES:

SAFETY:

• Ensure consistent enforcement of Safety policies including PPE use
• Communicate safety awareness as primary to all employees; maintain safe working conditions; propose ideas to improve the safety within the plant
• Responsible for appropriate safety trainings and safety communications to employees
• Ensure timely (24hrs) incident reports are filled out with details of incidents to aid in quicker resolution of the issues
• Involvement in Safety walk-through audits to ensure appropriate operator participation and ensure appropriate follow-up is taken on findings
• Actively supports their employees participation in safety programs and teams and makes all necessary resources available to support those efforts on a routine basis

QUALITY:

• Ensure the close adherence to the production schedule in compliance with our quality standards
• Ensure consistent communication and enforcement of company Quality policies, GMP compliance, and all Food Safety regulatory standards
• Ensure timely communications with QC in order to have timely support to help address and problems or changes that could require a control or validation (i.e. Swabbing, checking product vs. standards, etc.)
• Maintain a high level of sanitation and housekeeping at all times
• Ensure that all processing equipment is properly sanitized and CIP'D before manufacturing starts
• Product protection/food safety - always be alert to any potential sources of product contamination.
• Ensure appropriate follow-up, review and development of corrective actions following any Quality Hold & Foreign Material reports
• Participation & involvement in monthly self audits & implementation of assigned corrective Actions arising from internal and external audits

PROCESS MANAGEMENT:

• Ensure close adherence to the daily schedule through close management; monitoring the on-line percentage, pounds per on-line hour, and using adequate/budgeted staffing/headcount, to ensure a high plant service level
• Ensure shop floor presence at all times possible to ensure issues that arise with the lines are addressed in a timely manner
• Ensure the organization, housekeeping, zoning, and GMP’s of the mixing/batching/packaging lines are maintained at all times
• Apply technical understanding of the packaging lines and their operation, in order to aid maintenance and operators identify root causes and quicker troubleshooting of the issues as they arise
• Ability to time manage all daily activities to ensure adequate shop floor presence is balanced with administrative duties and any meeting requirements
• Daily awareness of any products on HOLD and the coordination of the rework process to ensure timely disposition of products on HOLD
• Understand the technical aspect of CIP (Clean in Place) systems, to be able to be the “go to” person for operators when they have issues with CIP performance
• Develop a good understanding of the entire process from raw materials reception to finished goods for an excellent decision making process regarding scheduling. Specific attention needs to be paid in anticipation for the next 24 hours
• Maximize online times for all lines with a target of 80% ie 20 hours production per day with 4 hr change over time. Focus on fast and efficient turnarounds.

PEOPLE MANAGEMENT:

• Recruit new employees; determine temporary labor needs; staff positions according to the schedule; ensuring a proper organization during the shift by creating a defined and respected break relief schedule
• Ensure appropriate labor deployment on the shop floor and ensure that all relevant HR policies are been followed. Ensure appropriate and timely follow up with HR for any violations of HR policies
• Utilize shop floor time to spend with operators to have a detailed understanding of their strengths, weaknesses and any training/education opportunities and build an action plan to improve the areas of opportunity
• Train employees in new machines/equipment and SOP’s and ensure training effectiveness in application of job skills
• Evaluate employees through performance reviews, ongoing coaching and feedback method

CONTINUOUS IMPROVEMENT:

• Continuously improve performance based on the key performance indicators
• Operational efficiency measuring uptime performance. To achieve world class uptime, constantly determine sources of unnecessary downtimes in changeover, breakdown, quality procedures and organization
• Monitor shift performance, coach team on that basis, constantly seek ways to improve through observations, data gathering, problem solving working groups and initiation of appropriate actions
• Develop a proactive mindset within the shift to ensure that problems are addressed without unnecessary delay. Liaise with the manufacturing team and provide them with relevant data and analysis to identify key issues and help in identifying solutions
• Effectively contribute to problem resolution by participating in and/or leading PSG efforts
• Swiftly communicate within the department with other shifts, maintenance, engineering, and plant manager about conditions which require attention or decisions

ENVIRONMENTAL RESPONSIBILITIES:

• Oversee the efficient implementation of quality standards, programs and processes to improve operational efficiencies and reduce/eliminate production waste and HOLD product
• Support environmental programs established within the organization to include initiating power conservation techniques by turning off lights, manufacturing equipment, and computers when not in use
• Ensure that operators are effectively scraping equipment down and throwing away oil based product, prior to wash downs to reduce liquid waste emission to city sewer system
• Proactively look for ways to reduce negative impacts on the environment

QUALIFICATIONS:

• Bachelor’s Degree in Engineering, Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or related field preferred.
• 5-7 years supervisory/management experience in a manufacturing environment required; food manufacturing preferred
• English language proficiency
• Lean manufacturing experience preferred
• Track record of problem solving
• Strong organizational skills and autonomy
• Leadership and outstanding communication skills
• Computer literacy required
• Ability to prioritize and meet deadlines within specified time constraints
• Ability to operate in a team environment
• Ability to adapt in a changing work environment

PHYSICAL REQUIREMENTS:

• Ability to safely lift 50 lbs
• Ability to work 12-hour shifts (Alternating Weekend Schedule)
• Ability to bend and reach files and cabinets where records are stored
• Office environment repetitive motion through computer use is required
• Manufacturing environment operating in areas where high noise, machinery, and chemicals are present