To lead, manage and control all the mechanical, civil and EI engineering, maintenance and project activities at Newton Aycliffe to ensure that both legal and company standards are adhered to and that the current and future targets for SHE, asset integrity and condition, reliability, production and fixed costs are achieved.
The Compounds Business has three manufacturing sites at Newton Aycliffe (UK), Sins (Switzerland) and Helsingborg (Sweden).
The job holder must ensure that both UK legal and company standards are met. They will be required to manage external interfaces with the competent authority in each country where they are relevant to the role (eg HSE in the UK).
Asset condition at Newton Aycliffe is aged in a number of areas, with some manufacturing lines utilizing obsolete equipment. The job holder will be required manage these vulnerabilities with a spares and investment strategy to balance the finite resources available against the engineering improvements required in the short, medium and long term across all the engineering disciplines.
Many engineering and maintenance systems / processes have been recently re-established and are working well. Engineering work management (SAP), preventative routines, RCAs for major reliability losses, CAPEX programmes management, and engineering procurement processes need to be maintained and further improvement ideas can be implemented where possible. The job holder will be required to lead or support their ongoing development and implementation of future changes to systems and processes..
The sites require high plant availability and reliability, with production split over 19 PVC compounding lines. Although the technology is similar across most lines there is a vast array of manufacturers / designs involved across the different lines.
Some lines manufacture to medical grade product quality and all engineering and maintenance procedures must comply with medical product requirements.
Effective liaison between the planning, operating and maintenance teams and external contractors is key to the sites’ success and the job holder will be required to provide leadership, coaching and influence to ensure this.
The job holder may be required to represent the business at external events and conferences and within INEOS engineering community.
Lead, manage and develop the Compounds Engineering and Maintenance Teams at Newton Aycliffe to ensure effective support to the site to deliver current and future targets for SHE, codal compliance, asset integrity, reliability, production and fixed costs.
Most important activities:
- Ensure compliance with INEOS Enterprises SHE & Engineering Requirements
- Coach, manage and develop 2 professional asset engineers to ensure defined statutory and INEOS engineering standards and requirements are understood and complied with including the Process and Behavioural Safety Principles.
- Lead the use of engineering and maintenance Best Practice and Engineering Excellence
- Develop and maintain KPIs to monitor engineering team performance
- Actively manage the competence and training needs of the team
- Develop and agree succession plans
Prepare, agree and ensure delivery of annual engineering / maintenance fixed cost budget. Lead the analysis of maintenance spend and the identification and implementation of cost improvement initiatives. Control and monitor spend / commitment to allow accurate forecasting and budget delivery.
Most important activities:
- Ensure compliance with work management systems which allow control of work and spend
- Develop and maintain KPIs to monitor performance to budget
- Lead regular expenditure reviews with team
- Develop bottom-up budget based on inputs for asset engineers
- Provide spend data to the finance team to allow for accurate cost forecasting
- Release purchase orders
- Act as primary contact for Purchasing and provide support to fixed cost reduction / procurement excellence initiatives
Manage the development and implementation of the Compounds engineering and maintenance strategy in support of wider SHE, manufacturing, business and purchasing strategies.
Most important activities:
- Define and implement strategy to replace engineering services, standards and procedures previously provided via the INOVYN SLA (ie relevant ICERs / ICEPs / Sis)
- Ensure all teams have a good understanding of the wider strategies, objectives and targets
- Oversee the development of equipment specific policies for all main plant items which includes spares, maintenance and operational requirements
- Develop and agree procurement policies with Purchasing for all equipment and services
- Lead annual review of engineering and maintenance strategy and all related policies
Provide functional support in own discipline and act as technical ‘gatekeeper’ to ensure that standards / specifications etc are updated and maintained and that there is access to further support as required (eg for other engineering disciplines)
Most important activities:
- Full understanding of relevant engineering standards and procedures to be able to provide coaching to teams
- Approve as required technical specifications to the engineering and maintenance teams to allow engineering work to be completed as necessary.
- Lead or oversee incident investigations, processes reviews and management team discussions
- Maintain awareness of changes to legislation, Best Practice, technology etc
- Develop and maintain links with other INEOS engineers and wider contacts to ensure a network of informal support options
- Ensure that team has access to engineering standards and guidance and functional support as required
Develop, implement and oversee use of a work management system for planned and unplanned maintenance and project work and plant overhauls which provides clear and safe control of work, defines interfaces between and responsibilities of the various teams / contractors on site and enables cost control / management whilst minimising the impact on production.
Most important activities:
- Define clear ways of working for ownership and management of work orders in SAP
- Develop MCRS / TORs for work management (to form part of MCRS for team as a whole)
- Develop processes to manage contractor activities
- Implement Best Practice overhaul methodology
Manage and ensure delivery of both the Capital Project programme across all three sites and a minor improvement projects (revenue) programme.
Most important activities:
- Develop and implement a robust process to manage the Capital Programme and ensure that potential projects are fully scrutinised and prioritised
- Provide monthly updates on actual and forecast Capital spend
- Lead and manage the sanction process for each project
- Ensure delivery of each project to agreed scope, timescale and cost.
- Develop, implement and oversee a minor improvements process for non-capital projects
Provide engineering leadership across the whole of the Compounds business and its support functions (including engineering, maintenance, projects, purchasing, HR etc) and contractors to ensure ongoing operational, asset and business improvements.
Most important activities:
- Act as figurehead and champion for engineering standards across all functions and with all contractors
- Own the asset life plan and ensure that asset replacement requirements have a clear technical case to support them
- Ensure that all production areas have relevant KPIs and control systems for reliability and utilisation and have robust loss accounting systems
- Support ops team training to ensure that all equipment is operated correctly
- Maintain links with other INEOS Engineering Managers to share learning, review ideas, identify potential synergies etc
Qualifications
Graduate engineer with 5+ years experience
Chartership would be an advantage
Experience in setting up and managing Maintenance contracts / Engineering Procurement
Technical Skills
In depth knowledge of engineer standards and process
Good working knowledge of relevant legislation
Strong set of engineering skills in design, development and troubleshooting
Budget control
Good understanding of overhaul methodology
Experience of managing CAPEX portfolios
Behavioral skills
Excellent adherence to standards and codal compliance
Leadership skills to build and develop a team
Strong influencing skills
Good analytical, conceptual and strategic thinking
Strong problem solving skills
Must display initiative, tenacity and concern for impact
Committed and flexible approach to work