Fibre/masterbatch Production Controller

PURPOSE

**To ensure** efficient running of Staple Fibre, Masterbatch Extrusion, and Recycling departments**. To coordinate the above production processes to produce quality products **to ensure that Belgotex customer service, volume and operational efficiency goals are realized through efficient production, adherence to plan and high-quality output of manufactured product.

SPAN OF CONTROL

This role is responsible for the Fibre, Masterbatch, Yarn Cut, Erema and Deconer operations.

KEY ACCOUNTABILITIES & OUTPUTS

Production Management - Deep Focus
- Plan job to run on the machines.
- Assign raw materials to the various runs. D365.
- Reconcile jobs once complete. D365.
- Plan changeovers.
- Check stock availability. D365.
- Approve colours during production.
- Match and develop new shades in conjunction with R&D.
- Approve colours during production.
- Follow up on breakdown and repairs.
- Order consumables from stores.
- Carry out minor repairs.
- Respond to lab reports.
- Monitor SILO stocks.
- Discipline employees when needed.
- Maintain Colour Register.
- Ensure weekly maintenance is complete.
- Arrange overtime when staff is absent.
- Liaise with suppliers on off-shades together with departmental manager.
- Respond to call outs.
- Supervise, monitor, and correct the **raw material usage** to ensure waste levels are maintained at acceptable levels.
- Production **OEE** is maintained within targeted parameters and **downtime** is minimized.
- Monitor and ensure the **correct set up and change of the machine** done by the mechanics or perform this function in the absence of the mechanics as authorised by the Manager.
- Executes **minor maintenance** as authorised by the Manager.
- Works together with the maintenance team to ensure engineering implements the maintenance and repair program, to **manage production equipment setup, calibration, and ongoing maintenance**. Such a program must:

- improve availability and reliability of the equipment.
- reduce unplanned downtime.
- reduce and /or stabilise the overall cost of production.

Operational Planning - Curiosity
- Provide daily production updates outlining the key focus areas of the shift. Content and format to align to the agreed Operations Strategy Framework.
- Contribute actively to allow the Fibre/Masterbatch Manager to report and give feedback to the **Integrated Business Planning** **(IBP)** processes, meetings, and projects, to achieve the strategic business goals.
- Work with the Fibre/production Manager to ensure the optimisation of the **weekly shift rosters** for the use of operators, forklift drivers and other shift personnel to ensure capacity requirements are met with the lowest cost.

Reporting and Documentation
- Makes sure that all shift production reports are up to date to report against agreed goals, IBP, and financial metrics to reflect the shifts performance and explain expenditure.
- Ensure that all processes, recipes, and production specifications are **documented** into required SOP and process flow formats and stored centrally as per agreed document management system.
- Ensure operators **follow** the most up to date SOPs and _transactional documentation_ to ensure consistency of process.
- Work with the Fibre/Masterbatch Manager to implement **continuous improvement** processes to improve output, reduce variability and manage operational constraints.

Financial Management - Courage
- Monitor and record the use of consumables / expenses incurred during the shift and be able to explain variances to budget to the Fibre/Masterbatch Manager.
- Ensure that procedures are adhered to prevent excessive maintenance and consumable costs are incurred.
- Reports on number of operators working against the shift roster and unplanned overtime expenditure against budgets and plans.

Safety, Health, Environment - We Tread Softly
- Supervise shift activities that ensure compliance with applicable safety, health and environment legislation and audit requirements.
- Ensure housekeeping is kept to **5S standards.**
- Ensure all waste (product and packaging) etc are removed and the general production areas is kept clean to maintain housekeeping standards.

People Management - Better Together
- Monitors the daily timekeeping of the direct reports.
- Proactively manages **performance and shift dynamics** to ensure that a fair, professional, and high-performance environment, aligned to the company values is maintained.
- Work with the Fibre/Masterbatch Manager for first line discipline (counselling or first written warning)
- Develop **individual and organisation capabilities** to build bench strength while delivering results now and in the future.
- Select, train, coach, develop, motivate, and measure the work performance of individuals within the shift to **encourage accountability** and promote **employee engagement**.
- Supervise shift employees in a manner that maintains a **healthy Industrial Relations** climate exemplifies the Belgotex values and