Manager, Operations/ Production - Excellent Benefits Package

Job Description:

The Operations Manager/ Production oversees the entire manufacturing process to ensure that production is on schedule and within budget. His/ Her responsibilities include determining workplace safety and health strategies, and overseeing manpower and resource planning. He/ She analyses production data and determines new strategies to enhance the efficiency of processes, which includes assessing the viability of new machinery.

Establish Planning and Production Scheduling:

• Utilise advanced planning and scheduling (APS) software to create dynamic production schedules that balance demand fluctuations with resource availability. Implementing finite capacity scheduling algorithms ensures realistic schedules that account for machine constraints and labour availability.
• Employ lean production techniques such as single-piece flow and kanban systems to synchronize production activities, minimizing work-in-progress (WIP) inventory and reducing lead times from order placement to delivery.

Evaluate Quality Management Systems:

• Deploy statistical process control (SPC) techniques like control charts and process capability analysis to monitor production processes in real-time, promptly detecting deviations from quality standards. For example, employing Pareto analysis helps prioritise corrective actions by identifying the most frequent quality issues.
• Implement root cause analysis (RCA) methodologies such as Ishikawa diagrams and 5 Whys to systematically investigate quality incidents, uncovering underlying causes and implementing preventive measures to forestall recurrence.

Develop Floor Tracking and Control Plans:

• Implement process/ technology to track work-in-progress (WIP) inventory movement in real-time, enabling accurate inventory management and production planning. Explore and implement systems/ processes to provide actionable insights for optimising production flow.
• Establish visual management tools such as Andon boards and production dashboards that display key performance metrics and highlight production abnormalities. Implementing standardised visual cues and color-coded status indicators enhances communication and facilitates rapid problem resolution on the production floor.

Assess Manufacturing Processes for New Products:

• Collaborate with design/ product development teams to conduct manufacturing feasibility studies and design for manufacturability (DFM) assessments, identifying potential manufacturing constraints early in the product development lifecycle. For instance, conducting feasibility/ tolerance analysis to ensure that product designs are compatible with existing production equipment and processes.
• Implement rapid prototyping techniques such as 3D printing and computer numerical control (CNC) machining to produce proof-of-concept prototypes for new product designs. Iterative prototyping and testing iterations refine product designs and validate manufacturing processes prior to full-scale production.

Develop Organisational Risk Management Frameworks:

• Create a risk register that catalogues potential hazards such as machine malfunctions, chemical spills, and ergonomic strains. For instance, implementing lockout/tagout procedures for equipment maintenance reduces the risk of accidental start-ups, safeguarding employee safety.
• Institute regular safety audits and hazard assessments, utilising tools like job safety analysis (JSAs) and safety observation cards to identify and mitigate workplace risks before they escalate into accidents or injuries.

Evaluate Supplier Performance:

• Conduct supplier scorecard assessments based on metrics such as on-time delivery, defect rates, and responsiveness to quality issues. Establishing tiered supplier relationships fosters collaboration and incentivizes continuous improvement efforts.
• Implement vendor-managed inventory (VMI) programs where suppliers monitor inventory levels and replenish stock automatically, reducing stockouts and streamlining procurement processes.

Assess Maintenance Strategies:

• Develop comprehensive equipment maintenance plans that encompass preventive maintenance tasks, predictive maintenance inspections, and reliability-centered maintenance (RCM) analyses. Regularly reviewing maintenance records and failure histories guides continuous improvement efforts and informs equipment upgrade decisions.

Manage Teams:

• Provide direction and guidance to Supervisors, setting expectations, and fostering a culture of accountability, collaboration, and continuous improvement. This may involve conducting regular one-on-one meetings, performance reviews, and team meetings to communicate goals, expectations, and feedback.
• Develop Supervisors’ capabilities through coaching, mentoring, and training initiatives, equipping them with the skills, knowledge, and resources needed to lead high-performing teams. This could include providing access to leadership development programs, workshops, and other related trainings.
• Promote workforce diversity and inclusion by championing initiatives to create a culture of belonging where employees feel valued, respected, and empowered. This may involve implementing diversity training programs, employee resource groups, and inclusive policies and practices.
• Influence team decision-making processes through effective communication, collaboration, leveraging diverse perspectives and expertise to drive innovation and achieve goals. This could include soliciting input and feedback from team members, encouraging open dialogue and constructive debate, and facilitating decision-making processes that are inclusive and transparent.

Assess Workplace Safety and Health Systems:

• Implement safety training programs covering topics such as personal protective equipment (PPE) usage, hazard communication, and emergency evacuation procedures. Conducting hands-on safety drills reinforces knowledge and ensures swift, effective responses in real-world scenarios.

Evaluate Energy Usage and Waste Generation:

• Conduct energy audits to identify energy-intensive processes and equipment, implementing energy-efficient technologies such as LED lighting and variable frequency drives (VFDs) to reduce electricity consumption. Installing energy meters and sub-metering equipment enables granular monitoring of energy usage patterns.
• Implement waste minimisation initiatives such as source reduction, recycling programs, and process optimisation to minimse waste generation and landfill disposal. Collaborating with waste management vendors to implement closed-loop recycling systems reduces environmental impact and operational costs.

Establish Financial Budgets and Plans:

• Develop detailed production budgets that allocate resources for labour, materials, overhead costs, and capital expenditures, aligning budget allocations with strategic priorities and production forecasts. Implementing zero-based budgeting principles ensures that budget allocations are justified based on operational needs and performance metrics.
• Monitor key financial performance indicators such as cost per unit, labour efficiency variance, and manufacturing cycle time, conducting variance analyses to identify cost-saving opportunities and operational inefficiencies. Implementing cost control measures such as standard costing systems and variance reporting tools enables proactive management of production costs and budget deviations.

Strategise Manufacturing Process Improvements:

• Develop and enhance existing operations/ production policies and processes for consistency and standardisation purposes.
• Facilitate cross-functional brainstorming sessions and value stream mapping workshops to identify process improvement opportunities and prioritize improvement initiatives. Implementing lean manufacturing principles such as 5S workplace organisation and kaizen events fosters a culture of continuous improvement and empowers employees to contribute ideas for process optimization.
• Utilise advanced manufacturing technologies such as industrial robotics, machine learning algorithms, and internet of things (IoT) sensors to automate repetitive tasks (where applicable), improve production efficiency, and reduce labour costs. Implementing digital twin simulations and virtual manufacturing environments enables virtual prototyping and optimisation of production processes before physical implementation.

Assist in Process Improvement Projects:

• Act as a project champion for process improvement initiatives such as Six Sigma projects, lean transformation initiatives, and total quality management (TQM) programs. Providing executive sponsorship and resource support ensures that improvement projects receive the necessary visibility and stakeholders’ buy-in.
• Facilitate cross-functional collaboration and stakeholder engagement throughout the project lifecycle, leveraging project management methodologies such as agile scrum and waterfall to ensure timely execution and successful implementation of improvement initiatives. Conducting regular project reviews and milestone assessments enables proactive risk management and course corrections to keep projects on track and achieve desired outcomes.

Lead Continuous Improvement Initiatives:

• Foster a culture of continuous improvement and operational excellence by promoting employee involvement, recognition, and empowerment. Implementing suggestion programs and recognition awards incentivizes employees to proactively identify improvement opportunities and contribute innovative ideas for process optimisation.
• Facilitate knowledge sharing and cross-training initiatives that enable employees to develop new skills and perspectives, fostering a collaborative learning environment that accelerates process improvement efforts. Conducting regular performance reviews and employee feedback sessions ensures that continuous improvement efforts are aligned with organisational goals and priorities.

Job Specifications:

Education and Experience:

• Bachelor's degree in engineering, manufacturing, or related field
• Minimum 8 years of experience in manufacturing, with 3 years in a leadership role
• Track record of improving processes and quality in manufacturing
• Familiarity with lean manufacturing, Six Sigma, and quality management systems

Technical Skills:

• Proficient in production planning and scheduling software
• Strong analytical skills for process control and root cause analysis
• Experience in maintenance management and predictive maintenance
• Knowledge of energy management and sustainability practices
• Familiarity with manufacturing automation technologies

Leadership and Communication:

• Proven leadership skills in driving change and leading teams
• Excellent communication to convey technical information clearly
• Ability to coach, mentor, and develop team members
• Strategic thinker aligning operational goals with organizational objectives
• Project management and Six Sigma certification preferred

Additional Qualifications:

• Experience in regulated industries is a plus
• Familiarity with Industry 4.0 technologies
• Willingness to occasionally travel for professional development and supplier visits

The ideal candidate is an experienced manufacturing professional with leadership skills, technical expertise, and a focus on continuous improvement. They should have a strategic mindset, excellent communication abilities, and a willingness to adapt to a dynamic environment.