Deputy Factory Manager

PURPOSE OF THE ROLE

The main responsibility of the Deputy factory manager is to ensure the production processes deliver products of maximum quality in a cost-effective, safe and reliable manner, while maintaining the factory assets in a cost-effective way to ensure safe and reliable production. The deputy factory manager is also responsible to lead and manage the process and maintenance function for the factory in terms of execution of strategic direction, resources and process excellence

TASK AND RESPONSIBILITIES

Development of asset preservation strategy

• Assist the Factory manager with the development of the asset preservation Strategy, AM objectives and operational plans
• Review the asset register for remaining useful life and compare to current asset condition to determine the remaining preservation strategy
• Evaluate previous year budget and expenses to determine the following maintenance budget and Asset preservation strategy

• Review the performance of the plant and line for the previous year to identify focus areas and new performance targets

Implementation of asset preservation strategy

• Define and implement maintenance standards for the department to ensure cost-effective and safe maintenance execution
• Translate the asset preservation strategy and AM objectives into plans, budgets and KPIs for the maintenance function and provide the resources to execute these plans
• Allocate the budgets and performance target to department coordinators

Management of maintenance effectiveness

• Oversee the effective execution of preventive and reactive maintenance work on the factories assets to optimise their performance at minimal costs and risks
• Evaluate the work orders for the week (status; backlog; schedule compliance; performance) and address any problems with the department coordinator
• Review and monitor the cost of maintenance (SAP & Excel maintenance sheet) and address any problems with the department coordinator
• Evaluate critical plant/equipment status to determine when to schedule a planned maintenance stop

Drive quality and eliminate defects through continuous improvement

• Drive continuous improvements in process and maintenance (KPI review meetings; defect elimination; small projects; recognition)
• Records all continuous improvement tasks/opportunities
• Hold CI review meetings with department coordinators to allocate responsible person
• Prioritise, plan and resource CI projects
• Ensures the master tile specification are valid
• Analyse the customers complaints to ensure the QC system is preventing defects reaching your customers
• Monitor daily/weekly QC inspection from the Lab to identify CI projects
• Identify issues in efficiency and suggest improvements

Lead, manage and direct People

• Manage and lead the department/team coordinators (leadership, objectives and holding team coordinators; tile/sanwrights accountable)
• Facilitate daily department coordinators operational meeting (Previous day performance, discuss key constraints and risk and agree on the daily plan)
• Source and manage relationships with external and internal suppliers, OEM, shared resource
• Organize workflow by assigning responsibilities and preparing schedules
• Determine the action plans and targets for the next week
• Overseeing and coaching (process and support) personnel for the development of future leadership of the business
• Train new employees on safe use machinery and SOP, procedures policies and company standards
• Identify refresher training requirements, schedule training (defect elimination)
• Evaluate and develop the work skills development plan for next year
• Evaluate and plan for the departmental rotational plan for next year
• Enforce and manage non-conformances to company policies, procedures, guidelines and company standards

Safety, Health and Environment

• Ensure compliance to SHERQ regulations and system
• Monitor and ensure (Monthly, weekly, quarterly, and annual) safety inspection are done and records kept
• Plans and coordinates Internal & External audits (ISO9001;OHS Audit; Risk audit)
• Monitor time and attendance (overtime, time worked; absenteeism) and address problem areas with responsible department coordinator
• Monitor SHEQR indicators and address problem areas with responsible department coordinator
• Ensure the safe use and regular maintenance of process equipment

Management of process

• Set daily/weekly/monthly production objectives and communicate them to the support and process teams
• Check and ensure production output are according to specifications
• Schedule KPI meeting, to review the previous weeks production and quality
• Compile the month end report (safety; production stats; quality; top defects; waste and cost)
• Compile Quarterly board reports (safety; production stats; quality; top defects; waste and cost - Projects)
• Monitor the quality of specification of raw materials and manage non-conformance from the non-conformance procedure

MINIMUM REQUIREMENTS

• NQF Level 6/7 Degree in an Engineering discipline - Mechanical,
• Electrical, Chemical or Metallurgy
• Postgrad qualification in financial management is advantageous
• 5 years post qualification engineering or process experience in FMCG or mining industry
• Willing to work long hours

BEHAVIOURAL COMPETENCIES

• Self-motivated and interdependent
• Ambitious, Result Orientation
• Sound Judgment and Decision Making
• Drives Performance and Holds People Accountable
• Plans, Coordinates and Executes well
• Problem Solver
• Change Leader
• Innovation
• Concern for Safety, Health and the Environment
• Develops others (Building resources in terms of people, succession planning)
• Teamwork & Collaboration

TECHNICAL COMPETENCIES

Asset Management

• Understand basic asset and maintenance management principles and best practices as defined in ISO 55000 and the AMIP Asset Management Framework
• Integrates and can explain how the factory contributes to the overall organization
• Understand the maintenance work management process and the responsibilities of the different role players
• Develop and evaluate contracts and contractors for strategic services such as compressed air, water gas and raw materials)
• Oversee defect elimination according to an agreed DE standard
• Understand the basic principles and best practices for Chemical, mechanical and electrical principles
• Explain opportunity cost, time value of money and how it affects decision-making
• Explain and quantify the value of an improvement
• Evaluate and plan asset replacement decisions based on the assets life cycle costs
• Quantify the value of improvements and justify them through a business case
• Apply project management skills to manage capital projects within budget
• Knowledge of the asset care plan development process and provide input to maintenance task and logistic requirement
• Knowledge on the processes and best practices for maintenance shutdown planning
• Process and analyse data by using basic Excel functionality
• Assess 5S in the work areas
• Choose appropriate spare parts control mechanisms
• Interpret and forecast demand patterns

SHE Risk Management

• Integrates Safety, Health and Environment (SHE) risk management into all support and process activities to ensure optimal business performance
• Pro-actively identifies, assesses, prioritises and mitigates against potential risks
• Continuously identifies opportunities to enhance SHE performance to protect employees, contractors, customers and company assets.
• Effectively embeds leading SHE management practices, identifies areas for improvement and recommends actions to address gaps