Operation Team Lead

Role summary:

Responsible to manage, supervise and develop a team of main production line crews starting from the Hot End to the Cold End processes efficiently to manufacture ROCKWOOL products according to specified specifications as per Production Instructions and Operating procedures.

General Job Functions:

1. Operation Efficiency and Control - Regular monitoring of production to achieve quality, quantity and on time delivery as per production plan - Achieve PKF targets.
2. Monitoring of Production Output - Effective monitoring of production progress to meet production output - Minimize process stop times and met targeted production output.
3. Production Quality Control - Effective managing of output quality to meet product specifications - Reduced production wastage and defect.
4. People Development - Continuous improvement on performance competency - Increased workforce competency.
5. Managing Organizational Health and Safety - Ensure a safe workplace and work safe culture - Reduced workplace injuries and increased workplace productivity.
6. Reporting - Provide timely and accurate submission of report for better decision making - Achieved on-time submission of report.

Quality, health & safety, service, continuous improvement, equality & diversity, and policies:

1. ISO 9001 Improvement.

Effective relationships with all key stakeholders (include customers internal/external):

1. Conduct regular briefings related to health and safety for workforce to work safely.
2. Ensure safety procedures and policies are fully adhered by all workforces.
3. Report any accident or injury to workforce.
4. Monitor and ensure that housekeeping in the workplace both internally and externally is maintained as per 5 S standards.
5. Provide on the job training to key operators to increase the performance competency.
6. Identify the training needs of each workforce and make recommendations to the superior for training.

Key responsibilities and activities include, but is not limited to:

1. Plan and organize the daily tasks for all mainline production crews.
2. Ensure the availability of raw materials in hot end and cold end areas.
3. Ensure all pre-audit checklist before production runs are completed and accurate.
4. Ensure MLK line is tested and ready to run production.
5. Ensure front end loader driver fills up charging silo with the correct raw materials.
6. Ensure coke bags are weighed and recorded before being used up or being slit open.
7. Ensure drop pit area is secured, cleared from stones and debris and sand bed is prepared as per instruction.
8. Ensure binder mixing and oil is ready all time as being instructed.
9. Ensure cold end is ready and well prepared before production starts.
10. Ensure all daily records are well documented, kept, accurate and reliable.
11. Ensure communication between hot end and cold end is clear and accurate on product changes, irregularities in process, technical breakdown, and iron tapping.
12. Ensure communication to relevant departments is clear and accurate.
13. Leading and motivating mainline production crews in identifying, monitoring, and analyzing of Root causes of process downtime and initiate to prevent or to correct the root cause.
14. Preventative maintenance concern areas which could lead to downtime.
15. Root cause of non-conformity products to prevent from reoccurrence.
16. Ensure that hot end operators monitor and maintain a stable cupola for consistent output.
17. Ensure that cold end operators monitor and proactive in identifying non-conformity products.
18. Provide regular feedback to superior, on the cupola process trends and problems.
19. Alerting the superior if there are unnecessary omissions, negligence and other irregularities in the mainline process that can affect processes and the wool quality.
20. Utilize workforce efficiently to ensure production is maximized with minimum problems.
21. Continually find better ways to improve the production efficiencies.
22. Ensure expendable items are being used wisely and efficiently.
23. Supervise and ensure that Quality Standard of each stage of production process is carried out as per work instructions and procedures.
24. Ensure that products are manufactured as per product specifications and meet the quality standards.
25. Raise Corrective Action Request (CAR) to relevant department if detecting any non-conformity products or process during incoming, in process and outgoing process.
26. Ensure employees are trained on the job and developed continuously to increase the performance competency.
27. Identify and discuss the training needs for each of the workforce with superior to improve the skills and competency.
28. Monitor and follow up on absenteeism, tardiness, sick leave and unpaid leave for the entire immediate workforce.
29. Manage production as per production schedule especially in terms of quantity, quality and delivery time requirement.
30. Motivate and help sub-ordinates to achieve process key figure (PKF) targets.
31. Ensure effective assignment of manpower to ensure efficient operation.
32. Liaise with Production Planner on the best sequence of process for better production sequencing.
33. Identify WIP quantity at designated process and location.
34. Inform production on any changes on buyer’s specification of change of delivery date.
35. Co-ordinate with Maintenance department to provide quick response to minimize downtime.
36. Identify faulty equipment or machinery and liaise with maintenance to rectify.
37. Plan and arrange with maintenance to check and repair areas of concern during planned stops.
38. Ensure that all necessary raw materials are available for production.
39. Ensure that the Hot end and Cold end supervisor is communicating accurately to minimize process stop times.
40. Proactive, make contingency plans for space, pallets, or steel cages for finished or semi products.
41. Provide regular feedback to Superior, the shift attainment of production plan.
42. Alert the Superior, instances, omissions, negligence, and other irregularities that can affect the adherence of schedule and plan.
43. Ensure that the sub-ordinates follow ISO procedures and work instructions.
44. Ensure products are produced according to Production Instructions.
45. Conduct routine checks on the line to ensure the products are produced as per product specifications.
46. Liaise with the Quality department to ensure that products meet the quality standards.
47. Provide daily report to the Superior detailing: Shift Key figures, Breakdowns, stop times and Maintenance work requests that need the superior’s follow up.

Requirement:

1. Diploma holder in technical field.
2. Minimum 3 years of working experience in supervisory level in a manufacturing environment.
3. Speak proficiently in English and Bahasa Malaysia.
4. Good communication skills and willing to work shift.
5. Lean/ continuous improvement qualifications and delivery experience.