Job Purpose
The Production Manager is accountable for all targets relating to QSCD (Quality, Safety, Cost, Delivery) and all Production lines, by management of a cross functional team of people. Responsible for driving Efficiency, Improvement and leading the evolution of the Production team & line to the future vision of the business. To be part of a team. Production Manager will lead and be accountable for driving deliverables and business change through the team and leading by example. Operational should demonstrate, guide, lead and encourage their teams to maximise efforts and encourage development by being an excellent communicator and motivator.
KEY ACCOUNTABILITIES
Core Values:
- SIMPLICITY - We keep business simple, easy to understand and focused on the key issues
- COLLABORATION - We work together, sharing ideas in an open, constructive style
- RESPECT - We encourage different backgrounds and styles of working and welcome diversity
- INTEGRITY - We are honest in all that we do
- TRANSPARENCY - We share information, highlighting problems as well as successes
- PERFORMANCE - We focus on delivery of business results before personal success
- Should adhere to all the safety requirements as defined in the H&S standards
- Lead the team by examples
- Ensure that all the Operators/ Operating Technicians/ Sr. Technicians working with them or around them should also adhere to all the Safety requirements
- Conduct Hazards Analysis and Risk Assessment (HIRA) in the work area and around the work areas
- Resolve the issues with the team while involving the entire team
- Understanding about the PPE’s required in respective lines and areas
- Understanding about the Chemicals used in respective lines and areas
- Identify and ensure that the PPE’s are available in each area in accordance with the HIRA
- Take ownership of and work to the quality plan for the area
- Should have thorough knowledge about Quality Parameters of the Product during operation
- Operator to be fully involved in all aspects of quality ownership. Understand and follow all relevant QMS procedures (e.g. ISO, HACCP, QC checks)
- Should not bypass any system which would affect quality of the product
- All operators to be aware of any C.C.P in the machine area and to take remedial action if outside limits
- Should ensure that the checks are conducted as described in the TAMU stations available at various locations
- All quality checks should be updated at the frequency set up in the quality checklist and signed off at the end of the shift
- All documents related to online quality checks should be filed on daily basis
- Production Manager’s responsibility is to ensure that the data are available when required
- Zero Loss Culture by adhering to all quality standards and implementing checks based on the standard routines
- All Operational TL to be aware of any C.C.P in the machine area and to take remedial action if outside limits
- Know where to find information on CCP points
- Train Operators/ Operating Tech. / Sr. Technicians to follow all the quality standards
- Production planning to be done based on Production Plan received from Supply Chain
- Planning for AM/PM to be done on daily basis based on the plans generated through Pragma
- Time Management is an important criterion for self as well as Team
- Delivering results within the agreed timeline
- Production Related Reporting
- Accurate reporting of Production volume and Line Reliability for the shift
- Operational TL should be aware of all Production Plan and should update it shift wise
- Corrective actions report to be completed for all quality failures with learning's identified and implement actions to resolve the issues
- Be aware of the procedure for completing and raising materials complaint forms and communicate non-conformance materials with the quality department
- Maintenance Related Reporting
- Raise, complete and Close all PM/ AM WO
- Prepares detailed reports on work activities and related issues for consideration by senior colleagues
- Track, analyses and prepare report to improve key maintenance parameters such as asset utilization, maintenance cost, PM compliance, schedule compliance
- Ensure that targeted and agreed Line efficiencies are delivered every hour
- Be part of the RCA team to diagnose the issues and take corrective actions immediately or plan for long term actions which would eliminate the issues
- Ensure that the line delivers the targeted efficiency within the first hour of operation after a changeover
- The Production Manager should have excellent knowledge and understanding of key processes in Process/Packaging can and NRB (non-returnable bottles) production lines from VDM, JBT, Adue, Krones, Sidel and OCME
- He should be able to monitor, interpret and adjust key operating parameters in order to optimize plant performance to agreed quality, reliability and material loss targets
- Be able to resolve Basic to Moderate Technical issues by being fully conversant on how to operate the plant, its operating processes, running checks and maintenance routines
- Will provide first line diagnostic and fault-finding skills. Have a full understanding of the site problem solving methodology and should Lead Operators, Operating Technicians and Sr. Technicians to conduct 4M, 5Ys and RCA process
- Support the technicians in the fault-finding process
- Be expected to supervise equipment AM maintenance, ensuring that lubrication and routines are completed to the required standards
- Ideally the TL will be fully conversant in all machine areas in order to cover for breaks
- Should not change any parameters on the machine without understanding the consequences and should have a mitigation Plan in place in case of any failure
- Support the Predictive Maintenance TL in the fault-finding process
- Be expected to maintain equipment, ensuring that lubrication and routine checks are completed to the required standards in line with Autonomous Maintenance. Train operators, Operating Technicians and Sr. Technicians to follow the schedule for all checks and lubrication
- Carry out Autonomous Maintenance engineering work under the guidance of the Maintenance Engineer
- Train Operators, Operating Technicians and Sr. Technicians to carry out all jobs based on the requirements
- Ensure that the equipment and the surrounding areas are clean
- Take responsibility for any maintenance associated to the machine area and lead Operators, Operating Technicians and Sr. Technicians
- Should be flexible to handle breakdowns in multiple machines during the shift
- Should ensure that the machines are handed over in a very clean and working condition at the end of the shift by the Operators of the machine
- Should be conversant with the tagging system, identify any issues with the machines and carry out corrective actions
- Plan to meet daily and weekly Production and scheduled requirements along with the Operational TL
- Provide production, progress, or changeover reports to Senior Managers
- Set up and verify the functionality of safety equipment
- Develop OPL’s and SOP’s for each machine
- Adhere to all applicable regulations, policies, and procedures for health, safety, and environmental compliance
- Should be able to stand in for the Senior Manager and able to lead the team of Operators, Operating Technicians and Sr. Technicians
- Ability to drive company Excellence Program and maximize performance in all areas, including health and safety, quality, waste, labor efficiency via measurement and analysis
- Plan an organize weekly window
- Attend weekly FI meeting when on shift and play an active part in site FI project and individual FI projects
- Should have Continuous Improvement and Lean Manufacturing skills
- Ownership for 5s areas and audits
- 5s daily activity management with shift
- Involve Team to conduct FI activities
- Manage daily AM/PM activity
- Communicate all the Production Plan to all the team under the TL
- Communicate to Team about the work to be carried out during the startups and verify all details of work completed during shut downs
- Ensure that the CIP is carried out effectively and the Machine is sanitized/ Cleaned as per the standards
- Verify that the team conducts all the required check on all the equipment’s and SOP’s for start-ups are followed
- Verify that all paper works are complete
- All start-ups should be done and all quality parameters should be in line with the parameters mentioned on the TAMU station
- Verify that during start-ups the equipment used for cleaning are returned back to the Shadow boards and all items are in place
- Communicate Plan with Team of Operators, Op. Technicians and Sr. Technicians
- Verify that product specs available and all size change equipment cleaned and ready to install prior to change-over
- Verify machine change over parts to be cleaned and stored
- Verify that correct tools should be used for change overs
- Change-over to be RFT and within time specs. Any failure should be fully documented
- Machine efficiency to be @ 95% within the first hour
- Schedule PM during shut down based on the Work Orders generated through Pragma
- Identifies issues which would have an impact on the Safety & Efficiencies and ensure that it is highlighted & addressed immediately either during the run or by planning a shutdown
- All safety related issues to be immediately closed after discussing with Senior Managers
- Train & Lead Operators Level 1, Operating Technicians and Senior Technicians to do PM and Breakdowns
- Details of all work carried out during PM and breakdowns has to be captured in details in the WO and will be updated in Pragma by the Operational TL
- Ensure that all the work is carried out in a systematic procedure as recommended by the OEM
- Asset care to be carried out recorded and clearly communicated across the shifts
- Verify that any outstanding issues which could hinder production at the start up has been addressed
- Verify for any outstanding routines to be completed
- Asset care to be carried out recorded and clearly communicated across the shifts
- Any outstanding issues which could hinder production at the start up to be addressed should be discussed with team and resolved
- Any outstanding routines to be completed
- To be completed during natural breaks and at the end of production
- To be clearly communicated across the shifts
- To be aware of and understand all running checks that need to be completed for the area
- Handover to cover any issues that are currently affecting production or have had an effect during production (machine faults, quality issues, or material failures)
- Verify that the machine area was handed over in an acceptable condition GMP 5s Silver standards
- Operational TL should have a team briefing with Team 10 min. before the Shift timings to communicate the issues and the plans with Team
- Develop/refine work plans and supervises discipline-specific maintenance crews and maintenance activities. Ensures work is completed within set timeframes and to required quality standards
- Plan Major Overhauls for Production Lines & ensure availability of spare parts prior to execution
- Train team to handle Basic to moderate breakdowns, change over, lubrication cycle
- Train team to handle AM/PM programs
- Motivates, develops and trains staff to ensure that the section has the necessary skill base and that staff are optimally motivated and enabled to maximize their potential and contribution to the company
- Communicate and Mentor all the team members individually and as a group and ensure good two-way communication concerning Operations
- Have regular 1-2-1 with team members to apprise them about their Performance
- Appraisal of the team members to be done every quarterly and recorded
- Team performance has to be recorded using Record Card System on daily basis
QUALIFICATIONS
Minimum Qualifications:
- Bachelor of Science in Engineering in Mechanical or Electrical/Electronic or recognized Engineering Qualification
- Minimum experience of 5-7 years’ which 3 years in similar role preferably in FMCG/ Soft Drink Industry
- Candidates preferred with TPM experience
- Computer literate (MS word, Excel, Power point & other related software)
- Strong leader ship personality, team playing and ability to encourage people achieve tasks
- Well organized with good communication skills and ability to work under pressure
- Able to coach and mentor team members
- Proven Managerial experience and management potential
Skills:
- Excellent English. Good planning skills
- Strong knowledge and understanding of company’s core business and business process
- Strong communication skills and an awareness of operating in a multicultural, multinational work environment
COMPETENCIES
- Can do attitude
- Highly Skilled with Technical Experience
- Problem Solving, Analytical Thinking
- Taking ownership by being informed, preventative and proactive instead of reactive across the shifts
- Organized with a high ability to multitask and manage workloads
- Flexibility and ability to support other areas
- Targets & results-driven
- Pro-active with a win-win attitude
- Highly Self-Motivated
- Adherence to agreed standards (H & S, S.O.P & OPL)
- Ability to interpret and use gathered information to improve process control
- Support the site training programmes, helping to develop and update training support materials
- Adherence to all the schedules set up by TL
- Support the site training programmes, helping to develop the operator group
- Spotting an opportunity
- Influential
- Organizational Awareness
- Capable to use assembly drawings, P&ID’s and manuals to tune equipment for operation
- Capable to use electrical Hardware & logic PLC principles to solve equipment problems
*Only applicants meeting the strict criteria outlined above will be contacted as part of the shortlisting process.