Production Process Engineer

Production Process Engineer.

Responsible for identifying improvements to production personnel usage, reducing waste to enable supervisory team to lead their teams more effectively. Optimizing plant operations, identifying and driving continuous improvement and development of efficient production process. Ensuring efficient and optimised chemical and raw material usage.

Process Optimization:

• Working with the Operations Manager, production supervisory team and operators, identify improved methods of working.
• Analyse and improve the efficiency of the galvanizing process, identifying bottlenecks and implementing solutions to increase total throughput, reducing waste and improving cost effectiveness of the production facility.
• Continuously monitor the production process to ensure it operates within established parameters, adjusting settings and making recommendations for process improvements.
• Continuously monitor chemical data from all process tanks, ensuring that chemistry is optimised for high quality, efficient production meeting cost targets.

Continuous Improvement:

• Lead continuous improvement initiatives using Lean or Six Sigma methodologies, focusing on enhancing process efficiency, reducing downtime, and improving product quality.
• Develop and maintain detailed process documentation, including standard operating procedures (SOPs) and work instructions for both manual and automated processes.
• Manage small-scale capital improvement projects with maintenance supervisor aimed at upgrading equipment, implementing new technologies, or improving plant processes.

Quality Control:

• Ensure that the galvanizing process meets the highest quality standards, conducting regular inspections and audits to identify potential defects or areas for improvement.
• Perform root cause analysis on any quality issues or defects, implementing corrective actions to prevent future occurrences.

Health, Safety, & Environmental (HSE) Compliance:

• Working with the HSE Manager, ensure that all production processes adhere to health and safety regulations, maintaining a safe working environment.
• Support risk assessments and hazard analyses on production processes and equipment, implementing control measures to mitigate risks.
• Ensure that the galvanizing process complies with environmental regulations, particularly in managing emissions, waste, and chemical usage.

Collaboration & Communication:

• Work closely with the operations, HSE, maintenance, and quality teams to ensure seamless production operations and to address any technical issues that arise.
• Provide training and support to production staff on new processes, equipment, or changes, ensuring smooth implementation and adherence to best practices.

Performance Monitoring & Reporting:

• Develop and monitor key performance indicators (KPIs) such as production throughput, crane utilisation, downtime, and defect rates, supporting daily production meeting and providing regular reports to senior management.
• Identify areas for cost reduction across the production process, from energy consumption to raw material usage, and propose strategies to increase profitability.

Management Responsibilities

• Foster a positive, motivating high-performing professional team culture.
• Provide production improvement views and ideas within the management and wider team to ensure business targets and performance are achieved.
• Work with the Operations Manager and Supervisory team to inspire and develop the operations team to provide an excellent standard of work from a highly efficient operation.

Person Specification

• Proven ability to analyse, improve, and document manufacturing processes, with knowledge of Lean Manufacturing, Six Sigma, or other process improvement methodologies.
• Able to collaborate effectively with cross-functional teams at all levels and work in a hands-on, fast-paced environment.

• Familiarity with industrial machinery, chemical processes, automation systems, and production technologies used in galvanizing.
• Good understanding of health, safety, and environmental regulations within a manufacturing environment.
• A self-starter who can work independently and drive improvements with minimal supervision.
• Excellent verbal and written communication skills to effectively liaise with internal teams (Operator to General Manger) and external suppliers.
• Proficient in Microsoft Office, particularly Excel.