Reports to the Quality Manager
No direct reportees
Financial responsibility: Responsible for the budget allocated to each of the projects he manages.
Job Summary:
Primarily responsible for maintaining and optimising thermal and chemical processes for material phase changes (calcination), and final board specifications at Board line. Key focus is on calcination efficiencies, final board product quality and process stability The Production Engineer manages projects to improve, modernize or bring production equipment into compliance in order to guarantee both the efficiency of the production line as well as the good level of product quality. - The role involves cross-functional collaboration with other departments: production, maintenance, global engineering team, global R&D team
Summary person specification:
High technical understanding
Process and project management skills
Effective Cross-Functional Collaboration
Continuous Improvement of processes
Capacity to manage a budget
Key contacts and relationships:
Internal: Plant Manager, Production Manager, Maintenance Manager, Engineering Manager, Central technical Teams
External: Suppliers
Key responsibilities specific to the role:
Process Development Projects:
Contributes to analyse existing situation, identifying areas for improvement of production lines and ensures the implementation of the resulting improvement work with the objective of continuously optimizing productivity
Participates in the technical definition of improvement projects (engineering, specifications, costings, etc.), in the choice of the best technical solution and its costing,
Coordinates and controls, for each project entrusted to him, the planning and execution of work on site: drafting of calls for tenders and specifications, choice of suppliers, management of supplies, monitoring of works and launches, in the framework of applicable HSE standards,
Participates in improving product performance/characteristics (Lambda, density, etc.), including for new products developments,
Looks for, wherever possible, the best available techniques for saving energy,
Ensures the drafting of the procedures and technical documentation necessary for the maintenance, production and HSE departments. Carry out technical training for factory staff,
Together with URSA central services, coordinates and controls the progress of studies of planned development projects.
Investments management:
Carries out the technical studies necessary for the preparation of investment files,
Manages the specifications, relations with companies, as part of the preparation and execution of the investment,
Monitors the technical installation of the investment until its optimal operation.
Guarantees the successful completion of the investment while respecting budgetary, technical, security and legal constraints
Other:
According to a timetable, regularly asked to provide technical on-call service during evenings and/or weekends.
Participates to visual management
Can be 6S responsible for selected area
Can manage Daily Production Reports
Flowsheet development, P&ID development
Develop mass and energy balances for existing and/or new process upgrades
Performs material and energy balances to diagnose and resolve material flow issues, energy optimisation and quality/process issues.
Writing process specifications, technical specifications to support quality optimisations, process control optimisations and plant throughput improvements.
Equipment sizing related to pumps, piping, conveyors, tanks.
Process knowledge related to solids material conveying, particle size reduction (ball mills, vertical roller mills)
Process knowledge related to calcining (advantageous)
Develop process specifications to support and work with Automation/PLC engineers for optimising process control loops.
Tracks and analyses daily operating data to optimise plant operational KPI’s
Supports work streams for compliance with regulatory requirements: SABS/NECSA/SAGA
Key Soft Skills & Proficiency Scale: Advanced:
Support daily plant troubleshooting related to material throughput in calcining and maintaining specific material flow and temperature requirements in calcining.
Support maintenance team in problem solving mechanical and electrical plant/equipment outages.
Support plant problem solving activities for process upsets: 5Why, Kaizen RCA, DMAIC.
Support Continuous Performance Monitoring and Continuous Improvement activities: visual management related to process tracking, OPL’s, startup/shutdown checklists.
Cost deployment support: loss tree analysis, material variance analysis and reduction of scrap,
Kaizen Focused Improvement: initiate and /or lead manufacturing process related kaizen improvements.
Process capability studies, with experience in reducing standard deviations on key process parameters related to calcining, milling. (advantageous, but not strictly necessary)
Initiate and lead plant trials in relation to process improvements, material and energy improvements.
High level of commitment
Structured way of working
Very good analytical and problem-solving skills
Creative - Strong communication and analytical skills - Working autonomously - Persistent - Adaptation skill
SHEQ:
Conduct HAZOP studies, support site risk assessments and work with EHS manager and Safety Project Engineer on CAPEX projects related to LOTOTO/Machine Safety.
Support daily Quality Management activities, QC at source as well as Quality strategic improvement activities.
Align with and ensure all company EHS standards maintained, comply with local regulatory requirements related to OSHACT and GMR.
Develop new or maintain existing SOP’s, Standardised Work and other Standardised operator documents.
Tracks and analyses daily quality related Process KPI’s to optimise quality and plant output.
To apply immediately for this position click here.