Warehouse Manager

Role & responsibilities

A. Production Planning & Scheduling

• Prepare and monitor daily, weekly, and monthly production plans based on customer requirements, sales forecasts, inventory levels, and production capacity.
• Coordinate with Production, Procurement, Quality, Sales, Maintenance, and Finance teams to ensure smooth execution of production plans.
• Ensure availability of raw materials, packing materials, and other production inputs as per the production schedule.
• Monitor production plan vs. actual production and identify deviations and corrective actions.
• Optimize production schedules considering machine capacity, manpower availability, material availability, changeover time, and customer priorities.
• Carry out MRP activities and ensure timely planning of material requirements.
• Update and maintain production planning and inventory-related data in SAP/ERP systems.
• Identify potential material shortages and take proactive action to avoid production stoppages.
• Prepare and circulate relevant planning reports and MIS to management.

B. Warehouse Management

• Manage the overall operations of Raw Material, Packing Material, Semi-Finished Goods, and Finished Goods warehouses.
• Ensure proper receipt, inspection, storage, handling, and issue of materials.
• Ensure timely and accurate GRN, material transfers, stock movements, and dispatch documentation.
• Implement and maintain FIFO/FEFO practices wherever applicable.
• Ensure proper identification, labelling, segregation, and storage of materials.
• Optimize warehouse space utilization and ensure effective storage practices.
• Monitor housekeeping, 5S, pest control, hygiene, and safety standards within warehouse areas.
• Ensure proper handling of rejected, damaged, expired, blocked, and hold materials.
• Coordinate with Quality and Production teams for timely disposition of rejected and hold materials.

C. Inventory Management & Control

• Monitor inventory levels of raw materials, packing materials, SFG, and finished goods.
• Maintain optimum inventory levels and prevent stock-outs, overstocking, and production interruptions.
• Conduct regular cycle counts, physical stock verification, and monthly stock reconciliation.
• Investigate inventory variances and implement corrective actions.
• Monitor and report slow-moving, non-moving, excess, obsolete, rejected, and ageing inventory.
• Develop and implement measures to reduce inventory ageing and carrying costs.
• Ensure accuracy of inventory records in SAP/ERP and physical stock.
• Coordinate with Procurement and Production Planning teams to optimize inventory levels.
• Ensure proper documentation and authorization for all stock adjustments and material movements.

D. Logistics & Dispatch Management

• Plan and coordinate finished goods dispatches according to customer requirements and delivery schedules.
• Coordinate vehicle placement, loading schedules, route planning, and dispatch priorities.
• Ensure vehicles are available on time and suitable for the required material.
• Monitor transporter performance and ensure timely delivery of materials to customers.
• Track OTIF (On-Time In-Full) performance and take corrective actions for delays.
• Monitor vehicle turnaround time and minimize vehicle detention.
• Coordinate with 3PL transporters, customers, sales teams, and internal departments for smooth dispatch operations.
• Ensure proper dispatch documentation, including invoices, delivery challans, e-way bills, transport documents, and other applicable records.
• Monitor transportation costs and identify opportunities for cost reduction.
• Resolve transportation, delivery, shortage, and customer-related logistics issues promptly.

E. Team Management

• Lead and manage warehouse supervisors, operators, executives, and contract manpower.
• Plan manpower deployment according to workload and shift requirements.
• Monitor shift-wise manpower utilization and productivity.
• Allocate responsibilities and ensure proper supervision of warehouse and dispatch activities.
• Conduct regular team meetings and performance reviews.
• Train employees on SOPs, safety, material handling, 5S, FIFO/FEFO, and warehouse practices.
• Develop employee capability and promote a culture of accountability and continuous improvement.

F. Quality, Safety & Compliance

• Ensure compliance with applicable GMP, 5S, EHS requirements, warehouse SOPs, and company policies.
• Ensure safe storage and handling of raw materials, packing materials, and finished goods.
• Ensure proper use of PPE and adherence to safety procedures by warehouse and logistics personnel.
• Maintain required statutory, operational, and inventory records.
• Ensure warehouse and planning documentation is maintained and readily available for audits.
• Coordinate with Quality, EHS, and other departments during internal, customer, statutory, and external audits.
• Identify unsafe practices and implement corrective and preventive actions.
• Ensure compliance with applicable food safety and hygiene requirements.

G. Cost Control & Continuous Improvement

• Identify opportunities to reduce inventory carrying costs, transportation costs, detention costs, warehouse costs, and operational losses.
• Improve warehouse space utilization and material flow.
• Implement process improvements to reduce material handling time and operational inefficiencies.
• Develop and monitor appropriate operational dashboards and MIS.
• Analyze operational data and provide recommendations to management.
• Implement lean, 5S, and continuous improvement initiatives within planning, warehouse, and logistics operations.
• Drive improvements in productivity, service levels, inventory accuracy, and customer satisfaction.

1. Key Performance Indicators (KPIs)

Performance will be evaluated based on, but not limited to, the following:

• Production Plan Adherence
• Material Availability for Production
• OTIF On-Time In-Full Dispatch
• Inventory Accuracy
• Inventory Days / Inventory Value
• Slow-Moving & Non-Moving Inventory Reduction
• Warehouse Space Utilization
• Stock Ageing Reduction
• Vehicle Turnaround Time
• Vehicle Detention Cost Reduction
• Transportation Cost Optimization
• Dispatch Accuracy
• Warehouse Productivity
• Safety & Compliance Performance
• Audit Compliance
• SAP/ERP Transaction Accuracy

2. Key Competencies

• Strong knowledge of Production Planning, Inventory Management, Warehouse Management, and Logistics.
• Good understanding of MRP and SAP/ERP systems.
• Strong analytical and problem-solving skills.
• Good knowledge of inventory control techniques and warehouse best practices.
• Strong coordination and communication skills.
• Ability to manage multiple priorities and work under pressure.
• Strong leadership and team-management capability.
• Good understanding of GMP, 5S, EHS, and quality requirements.
• Strong decision-making and execution skills.
• Cost-conscious and improvement-oriented approach.

3. Educational Qualification

• Graduate degree in Engineering, Supply Chain Management, Operations, Logistics, or a related discipline.
• Postgraduate qualification in Supply Chain Management, Operations, Logistics, or MBA will be an added advantage.

4. Experience

• 10-15 years of relevant experience in production planning, supply chain, warehouse, inventory, logistics, or dispatch operations, preferably in a manufacturing/FMCG/food & beverage industry.
• Experience in SAP/ERP-based planning and inventory management is preferred.
• Candidates with proven experience in managing warehouse and logistics teams will be preferred.

The position will be accountable for ensuring material availability, effective production planning, inventory accuracy, warehouse efficiency, timely dispatch, logistics performance, cost optimization, and compliance with safety and quality standards within the assigned areas.