Factory Engineer Manager

3 weeks ago

Johannesburg, South Africa Metamorphosis Integrated Solutions Full time

Location: Jhb North

Reporting to: Plant Manager

The purpose of this position is to fully support factory operations by managing all aspects of the engineering department. This Plant Engineering Manager will be responsible for the technical/engineering support and maintenance of machines, which includes the upkeep of
all manufacturing assets on site and driving day-to-day engineering support for all production areas. The incumbent will ensure world class maintenance strategies are implemented and followed with a key focus on efficiency and effectiveness of all maintenance tasks.
In addition, this requires a proactive approach providing technical knowledge to the various manufacturing functions including operations, quality, compliance, and health & safety. The incumbent will also be responsible for managing multiple shifts of a multi disciplinary engineering and maintenance teams.


Learning Required:

B.Eng. / B.Tech. in Engineering (Electrical or Mechanical).
10+ years experience in an engineering/maintenance management role.
Previous GMR 2(1) appointment is a must.
A Certificated Engineer (holder of Government Certificate of Competence - Factories) will receive preference.
Experience in FMCG/Pharma/Healthcare manufacturing and cGMP regulations will be a distinct advantage.
Qualification in maintenance planning and/or CMMS (Computerized Maintenance Management System) would be advantageous.
Good understanding and experience of current manufacturing technologies and methodologies.
Proficient in MS Office packages and MRP/ERP systems.
Excellent communication and interpersonal skills with the ability to effectively interact with and influence employees from a multi-disciplinary and dynamic team.
Must have demonstrated experience in mentoring/managing Engineering graduates in the workplace.


Responsibilities:

Health, Safety, Environment & Compliance:
o Ensure compliance in accordance with cGMP regulations, SAHPRA, FDA & OHSAct (Act No. 85 of 1993).
o Compliance in accordance with Group, Site or departmental regulations and protocols.
o Identify risks and draw up procedures to mitigate any potential dangers/hazards.
o Conduct regular toolbox talks on factory relevant topics.
o Review procedural standards on a regular basis and brief all department staff.
o Conduct and Chair monthly departmental meetings.
o Ensure all legal statutory requirements are met and maintained. This includes, but is not limited to, lifting equipment, major hazardous installations, pressure vessels, ladders, slings, etc.
Risk Management:
o Develop action plan to alleviate risks as per yearly Insurance Risk Report.
o Monitor site utilities (water, gas, electricity, steam, RO water, air) and develop action plan(s) to alleviate any potential risks.
o Establish and maintain a Smart Enterprise Asset Management system.

Machine/Equipment Availability:

Maintain production lines at optimal performance and drive continuous improvement to increase output, reduce downtime and waste through planned andpreventative maintenance.
o Tra ck machines planned and unplanned downtime and devise action plan(s) to increase planned maintenance and decrease unplanned (breakdown) maintenance.
o Ensure all maintenance tasks are planned for and executed within the forecasted timeframe and in accordance with set cGMP regulations and SOPs.
o Ensure all plant equipment and machines achieve world class OEE levels and manage sustainability thereof.
o Drive the maintenance and Reliability initiative, focused on Preventive, Predictive & Condition-based maintenance, not reactive.
o Identify and implement improvement ideas to enhance equipment operation, reliability, and efficiency of maintenance programs.
Maintenance Productivity
o Schedule, train, supervise and motivate employees to perform their best.
o Track and evaluate artisan/technician performance and devise action plan to correct poor performance.
o Coordinate work performed by contractors/3rd party vendors.
o Keep maintenance logs, analyze data and report on daily activities.
Project Management:
o Conduct, prepare and manage tenders for site specific projects.
o Understand and develop an Industry 4.0 roadmap to realize digital transformation in the engineering and maintenance fields, delivering real-time decision making, enhanced productivity, flexibility, and agility.
o Manage (and sometimes support) project start-up of new equipment.
Factory Expenses:
o Fully control all maintenance related expenses.
o Be fully capable of making informed decisions in terms of maintenance cost and distinguish between business-critical and business non-critical repairs.
o Investigate, search, and implement alternative solutions to avoid
exorbitant/unnecessary expenditure to better control expenses.
o Ensure efficient repair schedules and review repair cost estimates.
o Set-up budgets and meticulously control expenditure.
o Maximize machine/equipment availability and ensure worlds class OEE is achieved and maintained. 

Prioritize and properly plan maintenance and repairs of company equipment in line with OEM instructions and guidelines.
Develop and implement the necessary maintenance activities for assets which do not have OEM specifications available. 

Reasonable care and an experienced approach should be taken when drawing up these specifications.

Develop, revise & review related technical documents (Maintenance SOPs, Job Plans, etc.) and ensure implementation thereof.

Manage execution of planned maintenance of all company assets on site.
Support factory and participate in cross-functional teams to investigate nonconformances, deviations, and troubleshoot issues to establish root causes and corrective actions.
Lead and assist with identification of operations improvement initiatives and innovative solutions to manufacturing quality and H&S challenges.
Provide necessary training and continuous development for all maintenance and engineering personnel within your department.
Factory Engineer Manager
Coach and develop direct reports through regular one-to-one and formal Performance review process.
Set clear standards, objectives, and expectations for each direct report.


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