Continuous Improvement

Job Purpose:

The role will lead and coordinate the continuous improvement agenda to achieve cost of goods sold (COGS) benefits. It will focus on fostering a process improvement culture by developing programs, enhancing capabilities, and establishing a pipeline of initiatives to promote productivity over the planning horizon. The position will also oversee a transformational program while collaborating closely with Production, Planning, Logistics, and Quality to achieve agreed-upon total cost savings per annum.

This highly visible role offers significant exposure to senior leadership on a regular basis. The manager must showcase strong leadership skills and a commitment to delivering continuous improvement through team efforts.

Principal Accountabilities:

• Partner with key functions to develop and deploy productivity strategies that will drive COGS benefits.
• Build, execute, and sustain a multi-year productivity pipeline to drive annual savings.
• Deliver value to the business, typically measured in quantifiable savings or OEE improvement.
• Establish and maintain processes and systems for the communication, sharing, and best practice replication of process improvement initiatives across functions, supported by optimal digital presence and SAP4HANA capability.
• Develop recommendations and drive approved plans to activate continuous improvement capabilities.
• Utilize best practice continuous improvement methodologies to drive effective training and development of these capabilities, ensuring a sustainable continuous improvement culture.
• Develop relationships to successfully drive change, establishing credibility and respect among colleagues at all levels.
• Develop people by working with all levels, from the shop floor to management, to increase maturity and understanding of a sustainable lean culture.
• Identify and quantify improvement opportunities, deliver savings through improved processes, and independently lead projects.
• Train subordinates to ensure business continuity.
• Ensure engineering and technical services on projects and activities for the plant are scheduled and completed, and machines are maintained properly.
• Build effective working relationships with identified partners in alignment with business guiding principles, safeguarding the interests of the Group.
• Ensure compliance with relevant management systems certifications and timely, accurate recording of transactions in approved ERP, including related report submissions.
• Establish a continuous improvement dashboard for effective reporting and monitoring of efficiency projects.
• Establish and execute productivity governance reporting and review processes with key functions.
• Contribute to the establishment of vendor requirements and performance metrics to meet continuous improvement or efficiency standards.
• Supervise shift operations as required.

Health Safety, Security and Environment

• Enforce strict adherence to work permit procedures for all non-routine LOBP operations. To ensure that the work permit process is followed for all non-routine works at the LOBP.
• Enforce strict HSSE standards among all LOBP contractors, including mandatory use of appropriate PPE, tools, and equipment.

Procurement, Contract Management and Asset Management

• Manage the procurement process, from sourcing to payment, ensuring C&P policy compliance.
• Maintain an up-to-date asset register.
• Oversee the contract lifecycle, including drafting, reviewing, signing, and monitoring contract performance to ensure compliance and mitigate risks.

Project Management

• Collaborate with departments to implement projects.
• Post Implementation Review for major projects done.
• Lead equipment modernization initiatives to meet evolving business needs.

Performance Management and Development

• Conduct internal audits and drive corrective actions.
• Support continuous learning and development.

Troubleshooting

• Diagnose and resolve equipment breakdowns efficiently.
• Identify root causes of equipment failures and implement corrective actions.

Design and Development

• Design equipment modifications or upgrades to improve performance and reliability.
• Develop BOQs based on drawing concepts to sourcing end user needs.
• Design sketch or AutoCAD drawing development and interpretation.

Key Challenges:

• Delivery of incremental productivity savings through detailed project analysis in an increasingly lean operation.
• Building a sustainable continuous improvement culture within a dynamic changing workforce.
• Delivery across multi-functional teams and matrix organization.
• Change management.
• Prioritization of projects and balancing with continuous business needs. Adapting swiftly to evolving engineering advancements.
• Juggling multiple projects and tasks in a fast-paced environment.
• Guaranteeing the accuracy and reliability of automated systems and processes.
• Staying current with the latest advancements in PLC programming and industrial automation.
• Conveying technical information clearly to non-technical team members.
• Responding to the dynamic needs and priorities of plant operations.

Requirements

Job Knowledge, Skills & Experience:

Higher National Diploma in Technical qualifications either Mechanical or Electrical as minimum requirements, with preference on university degree in Engineering qualifications.

Professional certification in projects management, continuous improvement models include Kaizen for incremental change, Six Sigma, Lean Manufacturing PDCA, DMAIC, 5S and Poka-yoke, will be an added advantage.

Minimum 7 years relevant working experience including evidence of project and contractors' management.

Value Chain Management or Business improvement skill set including at least 4 years exposure and involvement in continuous improvement projects.

Proficiency in MS Office packages and working knowledge of SAP ERP.

Strong analytical skills

Excellent communication and inter-personal skills. Proficiency in Kiswahili is an added advantage.

Technical Skills

Knowledge in PLC programming with Siemens, Allen-Bradley, and ControlLogix systems, including ladder logic development, troubleshooting, and system integration.

Experience with maintenance management systems of filling line and packing HMI/SCADA systems.

Preventive maintenance automation and SAP PM.

IT Proficiency: skilled in IT, with strong proficiency in Microsoft Office Suite.

Core Competencies

Problem Solving: Utilizes exceptional analytical and troubleshooting skills.

Communication: Communicates clearly and effectively, both verbally and in writing.

Teamwork: Excels in team-based, collaborative settings.

Time Management: Effectively prioritizes tasks and manages time.

Attention to Detail: Ensures accuracy and precision in all technical work.

Competencies:

• Reflects HSSE commitment to employees and contractors.
• Fosters a climate of transparency, trust, and respect within team and cross functions.
• Recognizes opportunities to enhance outcomes through partnerships with contractors and suppliers.
• Assigns and reallocates resources to work effectively.
• Coaches, challenges, and provides opportunities for growth.
• Critical thinking and problem-solving skills.
• Planning and organizing
• Decision-making
• Negotiation skills
• Influencing and leading
• Delegation and teamwork
• Adaptability