Trainee Packaging Shift Manager

Purpose of the job

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 outputrequirements
• 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