Process Lead at British American Tobacco (BAT)

• British American Tobacco Kenya has positioned itself as a world class factory lean agile with high levels of productivity. This is supported by Integrated Works System (IWS). The Process Lead owns the integrity of the Line Event Data System and is responsible for data analytics of line losses. He/ She also act as the team’s expert in troubleshooting / problem solving. He/ She is the Centerline DMS, Changeover DMS, and Change Management DMS owner for the line(s). A majority of individual’s time will be spent on the floor working with the teams and building the capability of the people in their area. The job holder also has to operate within the legal framework defined by the prevailing labour laws.

Purpose Statement

• To develop the operating teams’ technical understanding and mastery of process control vital for achieving the Compelling Business Need (CBN) through meticulous application of Integrated Work Systems (IWS) tools.
• Is the Centerline DMS, Changeover DMS, and Change Management DMS owner for the line(s). The Process Lead owns the integrity of the Line Event Data System and is responsible for data analytics of line losses. He/She also acts as the team’s expert in troubleshooting / problem solving. A majority of the individual’s time will be spent on the operating floor working with the teams and building the capability of the people in their area.

Your key responsibilities will include:

Business

DMS Ownership

• Leads the Centerline Management system for the Cell, including:
  • Establish Center Line targets & limits for the equipment owned by the team
  • Ensuring all Center Lines audits are completed at the proper frequency
  • Develop control strategies to enable operators to respond to out of control   situations
  • Training team members on documentation needed when running out of Center Lines (CL)
  • Investigating, validating & updating new CL standards to eliminate losses
  • Driving weekly Health Checks, identifying gaps in system, and implementing appropriate countermeasures
• Leads the Changeover (CO) Daily Management System  for the line(s)
  • Establishing Changeover standards for all product SKU’s
  • Reviewing Changeover critiques and coaching shift teams to identify and implement improvement opportunities to achieve CO success criteria
  • Leading Rapid Changeover events to identify additional opportunities to reduce changeover time as required by business need
  • Performing weekly Health Checks
• Leads the Organisational Change Daily Management System (DMS) & validation processes
  • Including process benchmarking & reapplication across processes, modules and plants

Loss Elimination

• Analyses line data to identify and prioritize loss elimination opportunities including the creation of current state and future state loss trees using tools such as loss allocation and S-shape
• Shows direction inLine DDS process daily to set priorities and allocate resources, and report results for previous 24 hours:
  • Centerlines (CL) & Change Over (CO) Daily Management Systems (DMS)
  • Top 3 stops and initial finding
  • Process Failures and initial findings
• Using Reliability Engineering tools to drive Centerline Daily Management Systems and loss elimination
• Owns integrity of Line Event Data Systems (LEDS - ANT)
• Leads analysis of quality defects in Cell
• Initiate and lead in waste reduction activities across the factory

Troubleshooting & Problem Solving

• Leads root cause problem solving efforts on key chronic losses for the line(s)
• Coaches teams to build capability in problem solving skills and formal tools, including but not limited to Initial Problem Solving, Unified Problem Solving, 6W2H, and 5 Why’s
• Leads and builds the capability of team around process failures technical troubleshooting
• Use of visual management tools as improvement tools to aid in productivity and quality

People

• On the floor coaching of equipment owner
• Initial Problem Solving(IPS) / Unified Problem-solving (UPS)
• Coordinate SDWT team meetings and support their actions to deliver customer requirements.
• Facilitate and conduct training on RTT DMS’s and Focus improvement tools.
• Part supervision of equipment owners in the cell.
• Support the teams in carrying out  IPS/UPS and support implementation of agreed solutions
• Coordinate with Technical Operators, Technicians, Central Maintenance, Quality Assurance supervisors, Maintenance Lead, Line Lead (PMD & SMD) to ensure delivery of Customer requirements and address all customer complaints.
• Inspire the team by acting as a role model in terms of living the BAT guiding principles
• Support Line Lead to foresee possible issues and ensure smooth production process of the cells.
• Facilitates and encourages the interaction of the shift members and influences the shift's objectives and results.
• Provides support to other sections on site if required e.g. PMD, Engineering, Security, EHS etc.
• Consistently seeks for and encourages shift members’ ideas in respect of possible improvements and their implementation

What are we looking for?

 Functional Success Criteria

Success Criterion

Level

Description

Manufacturing - Tech Knowledge & Applications

Full Competence

• PRODUCTIVITY: Develops and implements best practise methods in material and product flow, layout and breakdown resolution to achieve optimal performance in asset/people/material productivity

Manufacturing - Processes & Control

Full Competence

• PROCESS OPTIMIZATION: Creates an environment where staff take ownership/accountability for enhancing the process and continuous search for ideas to optimise the process

Manufacturing - Regulatory Framework (EH&S)

Full Competence

• EHS: Translates EHS goals into actionable targets and empower others to achieve them

Manufacturing - Product Knowledge

Full Competence

• PRODUCT TYPES AND MATERIALS: Understands all the components used in the product and their impact on the final parameters and quality

Leadership Skills

• Ability to present to small & large groups and clearly communicate messaging
• Demonstrated leadership in the areas of safety and quality
• Demonstrated change leadership
• Interpersonal collaboration skills and seeks input from broader team
• Effective coaching and communication skills
• High level of personal responsibility and accountability for results

Management Skills

• Influencing, leading, and delegating abilities
• Ability to initiate/handle cross-functional teams and multi-disciplinary projects.
• Planning and organizing
• Result oriented: Ability to achieve the target within given time
• Good Communication skills.
• Negotiating skills
• Adaptability – Efficient under different working environment

Analytical Skills & Problem Solving

• Ability to work with data and information
• Intermediate Microsoft Excel skills
• Demonstrated ability to assimilate technical data to support recommendations
• Demonstrated problem solving skills
• Familiarity with structured problem tools, such as fishbone diagram, 5 why, RCA

Other Knowledge, Skills and Experience

• Minimum Diploma or equivalent experience in mechanical, Analytical Chemistry, Electronics or Electrical Engineering
• 3 years working in a factory setting
• Generate reports for the team
• Good Understanding of Knowledge of Secondary/QA operations
• Good social skills: Effective communication and influencing skills
• Leadership skills to assist in job deliveries

 Key Success Factors

• Quality of the data analysis and insights/ action plans from the analysis garnered
• Quality of the Initial Problem Solving & Unified Problem Solving for all major issues, (stops, Process Failures)
• Coach and train Technical Operators& Production Technicians staff in on Initial Problem Solving & Unified Problem Solving
•  Effective and efficient Brand Change process
• Facilitate collaboration within the Self Advised Work Teams (SDWT) through effective sharing of data and good practises
• Management of knowledge of good practices & lessons learnt and sharing the same across the Cell/Factory
• Inspire and empower the team through effective working relationships to improve performance

 Working Relationship

Internal:

• IWS Manager: To build organizational capability that aims for 100% employee engagement and zero loss mentality
• Technical Operators and Production Technicians; Effectively lead their performance through regular appraisal and effective coaching and delegate duties
• Other Line Structure (Team Lead, Maintenance Lead) Coordinate to formulate & deliver the 90 day plan according to the Compelling Business Need
• Line Lead, the Line Manager: To increase team alignment cohesiveness within Cell
• Central Maintenance Teams: To ensure all technical issues impacting on quality and modular output are addressed including availability and quality of crucial spare parts
• EHS Manager: To inculcate EHS values to staff
• Quality Manager: To develop a common understanding of product defects by all staff and their classification

External:

• Logistics Staff: To ensure all materials required are available, process improvement and resolving arising material issues
• Product Development  & QA staff: To ensure that new products and materials achieve good runnability and high quality output
• Ops Skills Development Manager: To discuss development needs of the staff, plan and complete development plans as vital