Process Engineer

The Process Engineer will be responsible for optimizing and improving the production processes within Bakali Foodstuffs (Pty) Ltd. This includes ensuring efficiency, maintenance, quality control, and adherence to safety and environmental regulations while working closely with cross-functional teams to drive improvement and innovation. Overseeing day-to-day operations, ensuring production efficiency, quality, and safety.

Key Responsibilities:

1. Process Optimization & Improvement:
   1. Analyse and evaluate the current manufacturing processes to identify areas for improvement in productivity, quality, and cost-efficiency.
   2. Develop and implement process optimization strategies to increase efficiency and reduce waste.
   3. Collaborate with the production team to ensure the seamless integration of new processes or technologies.
2. Operations Management:
   1. Oversee day-to-day operations, ensuring production efficiency, quality, and safety.
   2. Integrate within the team.
   3. Identify key players and obtain their overall buy-in.
   4. Key areas of focus:
      1. Production planning and schedules
      2. Reduce waste
      3. Improve controls
   5. Implement a formal floor walk process and procedure to identify efficiencies and improve production. Floor walks need to be documented and recorded to ensure momentum.
   6. Floor walks process:
      1. Policy
      2. Procedure
      3. Supporting Documents
3. Quality Control:
   1. Ensure all processes comply with internal quality standards and external food safety regulations (HACCP).
   2. Work closely with the Quality Assurance team to address product quality issues and implement corrective actions.
   3. Conduct root cause analysis on quality deviations and develop solutions to prevent reoccurrences.
4. Stock Control:
   1. Supply chain management.
   2. Procure stock.
   3. Stock classification – Raw materials, consumables and finished goods.
   4. BOMS allocation versus what has been consumed.
   5. Work with suppliers to reduce cost.
5. Project Management:
   1. Lead or support projects related to process improvement, equipment upgrades, and capacity expansions.
   2. Coordinate with external suppliers, contractors, and internal stakeholders to execute projects on time and within budget.
6. Data Analysis & Reporting:
   1. Collect and analyse data from production lines to track performance metrics (e.g., yield, downtime, efficiency and manpower required).
   2. Prepare regular reports on production efficiency, cost savings, and improvement initiatives for management review.
7. Technology & Automation:
   1. Assess the plant’s current technology and recommend new equipment or automation tools to enhance the production process.
   2. Implement automation solutions to improve productivity and reduce manual intervention in manufacturing operations.
8. Health, Safety Compliance:
   1. Ensure all processes comply with South African safety, health, and environmental regulations.
   2. Promote a culture of safety, including leading risk assessments and implementing safety measures to prevent accidents or hazards.
   3. Collaborate with the Safety officers to maintain safety protocols in the plant.
9. Training & Development:
   1. Train production staff on new processes, technologies, and best practices.
   2. Provide technical support and guidance to the production team to troubleshoot process issues in real-time.
10. Human Resources:
    1. Improve controls to ensure disciplines.
    2. Schedule staff and shifts.
    3. Improve staff morale.
    4. Reduce staff movement and wastage.
11. Maintenance:
    1. Oversee maintenance of machinery and facility:
       1. Preventive Maintenance
       2. Corrective Maintenance
       3. Equipment improvement (cost, output, efficiency, and electricity consumption)
       4. Maintaining workshop clean and equipment in good working condition.
12. Teams:
    1. Big Rice cake department
    2. Coating rice cakes department
    3. Mini Rice cakes department
    4. Corn Bite department
    5. Snack Farm
    6. Admin
    7. Quality Control
    8. Stock Control

Qualifications & Experience:

1. Bachelor’s degree in Engineering (Industrial, Mechanical, or Chemical Engineering).
2. 5+ years of experience as a Process Engineer, preferably within the food manufacturing industry.
3. Familiarity with lean manufacturing principles and continuous improvement methodologies.
4. Knowledge of food safety and quality standards (HACCP).
5. Proficiency in data analysis.
6. Strong problem-solving skills and attention to detail.
7. IT programming skills is an advantage.

Skills & Competencies:

1. Excellent analytical and troubleshooting abilities.
2. Strong project management skills with the ability to prioritize and manage multiple tasks.
3. Ability to work collaboratively in a team-oriented environment.
4. Strong communication skills, both verbal and written.
5. Proficiency in MS Office Suite.
6. Process optimization ability.
7. Familiarity with automation technologies and equipment in food production.
8. Change management abilities.
9. Strategic thinking.
10. Strong leadership background.

Work Environment:

This position will be based at Bakali Foodstuffs (Pty) Ltd Samrand Centurion and will require occasional travel to other facilities or supplier locations.