To control and organise, on a shift basis, all the operating and logistics activities at the Newton Aycliffe site to ensure that both legal and company standards are adhered to and that the current and future targets for SHE, production, customer satisfaction and costs (fixed and variable) are achieved.
The site has a huge number of grades and relatively limited product storage capacity and so end to end management of the production and site logistics operations is crucial to ensure that output is not impacted. This requires the job holder to have a thorough understanding of logistics operations in addition to process operation skills.
The role covers 4 plant production areas (C1, C2, C3 and C4) with 19 production lines plus out of hours warehousing operations for both raw materials and finished product. Some products from C3 form the raw materials for C1. There is very limited inter-changeability from one production line to the other which adds complexity to the operational planning aspects of the role.
Asset condition is poor. Although improvement work is underway reliable operation of the site is a significant challenge due to the aged and poor condition of much of the equipment.
Although a non-COMAH asset the site is operated to the same standards as a COMAH site using the same systems and processes including compliance with the increasing number of mandatory INEOS requirements, many of which are intended to safeguard against COMAH level risks. There are currently significant gaps to some of the requirements and a key aspect of the role is to lead the delivery of improvement in this area.
Accountabilities of the job: describe the main results expected from the job:
Accountability 1:
Lead and manage the operating and warehouse / logistics aspects of the manufacturing operation to ensure that legal, company and medical standards are adhered to and that delivery of current and future targets for SHE, production, customer satisfaction and costs (fixed and variable) are achieved.
Most important activities:
Demonstrate safety leadership through visible safety promotion, engagement with employees / contractors and challenging of behaviours
Leading the implementation of the necessary improvements to operational SHE systems (eg Permit To Work) to comply with legal and business requirements (eg INEOS Group Guidance Notes)
Leading the implementation of Standard Operating Procedures for all operational areas
Ensure all KPIs are met and are reviewed / monitored for all aspects of the operating operations and that systems are in place to deliver corrective actions when needed
Ensure compliance with INEOS Life Saving Rules and 20 Principles
Accountability 2:
Lead, manage and develop direct reports and their teams to improve their effectiveness in line with agreed objectives.
Most important activities:
Select, coach and manage the performance of individuals to ensure defined statutory and INEOS standards and requirements are understood and complied with
To maintain correct discipline procedures, records and harmonious industrial relations
Lead the use of operating Best Practice and Manufacturing Excellence
Review KPIs to monitor team performance
Actively manage the competence and training needs of the team
Develop and propose succession plans to the Plant Manager and HR
Lead the development of Team flexibility and skills to increase cover options and minimise the likelihood of uncovered berths
Accountability 3:
Lead the development and implementation of and ensure compliance with the site aspects of the S&OP (Sales & Operational Planning) process to maximise EBITDA and delivery of the business plan, working with the Plant Manager to ensure effectiveness of the overall, cross-functional process.
Most important activities:
Monitor analysis of production performance through the year and monitor operational capabilities (plant and human)
Through the S&OP process understand market changes and changes in demand / customer requirements and the likely impact upon operating requirements.
Accountability 4:
Provide operating leadership across the whole of the site and its support functions (including engineering, maintenance, projects, purchasing, HR etc) and contractors to ensure ongoing operational and business improvements.
Most important activities:
Act as figurehead and champion for operating standards across all functions and with all contractors
Monitor all relevant production area KPIs and control systems for reliability and utilisation
Support operating team training from other functions (eg engineering) to ensure that all equipment is operated correctly.
Level of education & Experience
Education to NVQ level 4 is required, or equivalent
Also, a high standard of management and communication skills at all levels.
Operations Management / Line Management experience
Minimum of 5 years experience in a manufacturing environment
Technical skills
In-depth proven manufacturing experience and technical evaluation of issues
Performance management
Good appreciation of regulatory and legal framework
Organisational skills and planning knowledge
Able to think outside the box
Behavioural skills
Leadership skills including the ability to motivate a wide range of staff directly and indirectly.
Excellent communicator
Tenacity
Integrity
Results orientation – performance bias
Strong interpersonal and management skills
Ability to influence, motivate and develop individuals
Ability to interface with people at all levels and build relevant relationships and networks
Change management skills
The role will work in line with the shift pattern which is 2 x 12 hour day shift, 2 x 12 hour night shift followed by 6 days off. 16 days summer break and a 10 day break at Christmas.