Position description / overview:
To manage, monitor and implement Continuous Improvement initiatives to plant, equipment and processes in order to optimise utilisation of organisational resources
Responsibilities:
Process Controls:
Plan, schedule and monitor production (Sales requirements, stock levels, maintenance requirements, changeovers, etc.).
Schedule and arrange change-overs according to the Production Plan (change-over sequence, tool changes, cutting knives, water jet nests, etc.).
Capacity planning and calculation to determine overtime / planned stop requirements.
Production Management:
Optimise the production process.
Maintain manufacturing and production efficiencies.
Ensure the optimal and efficient use of resources.
Balance the production lines (manning levels).
Monitor the achievement of daily production targets.
Analyse daily variances and identify opportunities for improvements.
Investigate and resolve manufacturing related problems and sub-standard performance.
Project Management:
Schedule project activities to facilitate effective project execution.
Raw Material Management:
Monitor the level of production material to ensure sufficient material to support production.
Lean:
Train Lean Modules.
Implement Lean in all factories: 5S Std. Work, Quick Changeover, Kanban, Constraints Management, TPM, Visual management, VSM (Value stream mapping), Roll throughput yield (First time right) / Rework reduction.
OEE:
Drive specific action items to improve OEE / OPR.
Develop and implement headcount management tools to accurately predict the no. of heads that labour needs to be flexed by, or the expected overtime requirement due to excessive orders.
CI / Innovation:
Leading and facilitating continuous improvement efforts by directing relevant staff.
Training and improving continuous improvement staff to meet required KPI's.
Research new equipment technology & promote innovation.
Coordinate Kaizen improvement initiatives at plant level.
Champion problem solving activities b.m.o. 6 Sigma.
Define and implement MES (Manufacturing Execution Systems).
Continuous improvement:
Monitors continuous improvements and makes suggestions to maximise production output.
Best Business Practice (BBP):
Assist Operation Manager to define BBP (Best Business Practice) criteria.
Systemize the collection and reporting of BBP data.
Use BBP info to leverage the implementation of a specific plant's best practice in the other plants. E.g., Implementation of PE's ability to use cheaper chemicals in the Rosslyn plant.
Quality:
Create Control Plan templates to increase comprehensiveness of Control Plan and reduce new project control plan compilation time.
Actively participate in the reduction of COPQ (Cost of Poor Quality).
Analyse audit reports/result in terms of repeated deficiencies, reviewing with process owners.
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