Purpose of the job – Trainee Packaging Shift Manager
To manage the packaging line operations, in line with the business goals and objectives, in order to maintain a high efficiency, low cost, good quality and acceptable safety standard operation. To implement company’s manufacturing processes, systems and procedures
Safety:
- Ensure all safety PPE audits, safety alerts, Tool box talks are done on time and in full according to safety Heineken Safety standards.
- Act as a role model for safety behavior and lead by example
- Address unsafe behavior and situation and act immediately in case of unsafe behavior and conditions and explain the reason to the people involved
- Ensure awareness to raising safety tags on shift and there is output in terms of tags raised and tags closed on shift
- Ensure visibility of tags raised in your the team, closure rate and feedback to the respective team members
- Liaise with safety department to timeously close out all investigations and gaps identified through incidents, accidents and near misses on your shift
- Ensure adherence to stipulate 5s and housekeeping standards by doing daily Audits on Machines
- Ensure that a reliable safety reporting for DCS and safety pyramid
- Carry out risk assessment and safety audit in your line(s)
Packaging Quality Management & Control :
- Ensure product quality in packaging
- Make sure that ISO/HACCP/Legal/Heineken Procedures and requirements are followed
- Monitor and communicate the packaging quality parameters within his/her team on daily basis in DCS
- Restore basic conditions where there are deviations
- Ensure all specified quality standards are adhered to on shift and adequate audits happen to ensure adherence
- Ensure all tools needed for quality control on shift are available through liaising with all available support
- Take prompt necessary corrective actions for OOC’s and liaise with all stakeholders to fix any rework on shift and ensure loop closures
- Identify key areas of improvement in quality related to reduce rework
- Carry out daily CILT audits on machines to ensure adherence to standards
- Explain the impact of quality issues on business performance ( i.e. Cost, customer service) to the team on regular basis
Cost Management:
- Execute basic deployment of department an line cost according to TPM principle
- Use correct financial language when communicating decisions
- Identify and manage areas of loss on the line through process area monitoring on shift and report and action OO’c
- Form focus groups for all high loss areas identified on shift and plans to get back into control
- Ensure all counts are done after every brand change and raw materials are returned after each and every brand change
- Ensure adequate explanation to all losses on shift through use of process area monitoring
- Ensure all consumptions are done on time and in full daily
- Manage overtime closely by measure cost per hectoliter
- Identify focused improvement projects for team members in specific areas
- Measure losses per process area hourly and have action plans for OO’C
Management of Packaging process and Execution:
- Clearly communicate daily activities to the staff and correct when necessary
- Monitor, manage and control daily packaging activities to make output requirements
- Organise and mobilise resources to overcome problems in day to day operations in order to deliver the agreed process output
- Translate process deviations into corrective and preventative actions and communicate in a timely way to the team
- Execute TPM improvement activities
- Plan resources (people, materials, machines) adequately against production plan to ensure desired output by:
- Shift cover is adequate according to standards, raw materials are ordered to the right standard
- All people on training, leave or extended planned leave have planned cover for that period
Change over planning:
- Change over plan is completed and communicated with team before changeover
- Pre and post checklist are completed as per standards and all faults rectified before changeover
- Changeover times are adhered to at every machine as per stipulated Heineken standards
- Progress for every machine tracked with start up with consideration to filler start up
- Changeover reports completed and handed over
- Action plans updated and actions completed fully on time
- SMED list are consistently used for every machine during changeover
- Necessary changes to SMED are communicated to the relevant people to update shared documents
- Changeover times are recorded accurately as per standard on MES
Maintenance Management:
- Ensure effective use of CILT time
- Regularly checks and coaches team on completion of CILT
- Identify CILT anomalies and take remedial actions
- Encourage tagging and de-tagging activities
- Participate in AM audits
- Ensure all down time activities is properly recorded
- Ensure 5 WHY is completed on shift for all DT within stipulated standards
- Ensure prompt adherence of team members to standard escalation procedures
- Operational resources are planned adequately to maintenance activities
- Team leader identifies work to be planned for maintenance on shift and request work from IC
- Monitor and report machine daily and weekly performance and availability with improvement plans
- Manage Planned Maintenance activities, especially shutdowns and star-ups in conjunction with central MTCE team and IC Support Exceptional Maintenance Activities
- Identify opportunities on the shift and the line to drive KPI improvement
- Ensure effective communication between production and Maintenance department
People Management:
- Spend 80% of time on the floor and 20% on administrative tasks
- Hold daily consistent handover meetings with team Members
- Ensure continuous handover across shifts and within the team members
- Coach direct reports on gaps identified
- Manage attendance and manpower requirements
- Motivate shift teams to achieve production targets through focused meeting agendas
- Identify opportunities on the shift and the line to drive KPI improvement
- Apply Performance Management Practices consistently with direct reports
- Manage and apply industrial relations, including disciplinary practices
- Implement training and development initiatives for employees
Education:
- Relevant National Diploma/ Degree in Engineering field
- Knowledge of SAP is added advantage
Experience:
- 5 – 8 years relevant experience in packaging environment
- Should have managed a team before
- At least two years at supervisory level
- FMCG experience is a must Packaging experience preferably bottling, canning of beverages
