Job Purpose
This position is responsible for the long-term and short-term planning, organising and overseeing all areas of plant operations including employees, productivity and efficiency to ensure the plant is running smoothly, quickly, efficiently and safely.
Main Responsibilities
Departmental Strategy formulation and implementation
- Develop, implement and monitor the Plant Operations strategy/business plan to ensure that the plant operates optimally is aligned to Heineken and the overall organisational goals and objectives
- Drive the development and implementation of future fit plant/ factory strategies, policies, procedures, and overall team to optimise value of the entire department in creating a world class supply chain function.
- Motivate and lead changes in technical processes, products recipes, changes in technology, culture change, structural and other strategic changes in the Plant Operations environment and the business at large.
- Conduct research on plant optimization and outline the future vision and automation of the plant. This includes but is not limited to identifying future automation needs, new production lines, the evolution of plant operations, and the necessary skill sets for personnel to achieve the desired future state.
- Develop business cases to support these initiatives and present them to the management team for decision making
Departmental annual budget
- Develop, implement and monitor the Plant Operations budgets to ensure that the plant operates optimally is aligned to Heineken and the overall organisational goals and objectives
Management of Technical Projects
- Develop and execute relevant technical projects and processes to improve the plant capacity and efficiency in adherence to project timelines and budgets.
- Review technical method statements of all the contracted work out to third party contractors to ensure safe execution
Conformance to Quality, Product and Process Specifications
- Drive conformance to quality management standards ensuring timely execution of recovery and improvement plans for any identified deviation and trends.
- Define and enforce adherence to work procedures and processes including updating the processes where necessary to achieve a seamless flow of work across the departments
Food Safety Systems Management
- Ensure full compliance to Food Safety Systems Certification, ISO 22000:2018 FSSC V6 on Site
- Support all the New Products Development, NPD (for New to World Projects) & Pack - Upgrades (PUGs) in such a manner that upholds Site Food Safety Standards.
TPM/ Champion of Operational Excellence & Continuous Improvement
- Drive optimization and improvement of the systems and the work process
- Entrench TPM2Win as the driving engine for Factory Operations
- Enhance productivity and service levels aligned to business needs by creating an environment that challenges status quo and promotes innovation
- Drive the utilisation of available automation/ digitization, ERP in the day-to-day operations of the plant
- Ensure KWAL integrated management systems (ISO 14001 and ISO 45001) are continuously reviewed and take necessary corrective and / or preventative actions on the identified findings and drive closure in a timely manner
- Oversee the overall program for asset care, utilities and facilities management to ensure optimal plant operations are safe and efficient use in the business.
Controls and Compliance in Plant Operations and Associated Processes
- Build strong internal control systems (ICS) with proper segregation of duties (SOD)
- Ensure plant operations processes are well optimised and controls are always sustained in line with Heineken standards
- Ensure total compliance with all the legal, statutory, regulatory and contractual requirements to maintain the licence to trade for the business and avert risks due to non-compliance.
Health, Safety and Sustainability Responsibility
- Identify safety and risk issues and establish corrective measures to promote a safe working environment in line with legal requirements and Heineken standards.
- Driving a Positive Health and Safety Culture in the workplace and playing a lead role in the Occupational Health and Safety Committee on Site.
- Manage and control emissions to the air – e.g. boiler stack emissions of flue gases, generator exhausts from combustion of organic fuels and sonorous emissions/noise pollution
- Manage and control of emissions to water surfaces including storm drains & sewer systems and effluent discharges
- Manage and control emissions to land e.g. solid waste from site
Inventory Management
- Ensure proper management of critical engineering spares and process consumables
- Oversee and ensure prudent management of fuels, lubricants and other Consumables
- Daily management and controls of Extra Neutral Ethyl Alcohol (ENA) stocks and blended products in the cellar
- Manage stocks under Work in Progress (WIP) for goods under conversion in the packaging hall
- Ensure optimal and secure management and reconciliations of Tax Stamps in the packaging hall
Reporting
- Prepare and submit accurate and timely management reports for decision making
People Management
- Establish systems to attract, develop, engage performance management and retain talented individuals
- Create an environment where staff can realise their full potential and contribute to the attainment of departmental and organizational goals
- Create a sense of common purpose within and across packaging, brewing and engineering to facilitate the timely delivery of quality products at the right cost and in the right quantity
- Drive continuous improvement within the Factory environment
- Represent the Business Leadership in the biennial negotiations of Collective Bargaining Agreements with the Labour Unions (representing Unionised employees).
Minimum Required Qualifications, Knowledge and Experience
Academic Qualifications
- Bachelor’s degree in Mechanical Engineering, Manufacturing/ Production Engineering, Electrical Engineering or Food Science and Technology
Professional Qualifications
- Membership to a professional Body e.g. EBK
Experience
- At least 8 years, 4 years’ experience in management role in a manufacturing company
Competencies
Technical Competencies
- Ability to manage complex technical projects, proficiency in computer systems & applications
- Excellent understanding of ERP systems applications
- High Aptitude in Occupational Health and Safety, including local safety legislation and the Heineken Life Saving Commitments
- Thorough understanding of asset care philosophies including a working knowledge of the Heineken Asset Care Standards (HACS)
- Good understanding of sensory science practices applicable to alcoholic and non-alcoholic beverages
- Strong product knowledge and expertise in manufacturing processes and applicable standards, including food safety system standards; good manufacturing practices etc
- Excellent appreciation of general engineering principles and their applications in food manufacturing.
- In depth knowledge of implementing requirements of various standards e.g. ISO 9001;2015 Quality System Management Standard, ISO 22000:2018 Food Safety System Standard, ISO 14001:2015
- Environmental Management System Standard, ISO 45001:2018 Occupational Health and Safety (OH&S) System Standard; Kenya’s National Food Safety Policy; The ATEX Workplace Directive-ATEX 137; Heineken Standards
- Excellent understanding of relevant laws/statutes and legislations in Kenya
- Competent in Budgeting, Budget Management with a cost-conscious mindset
- Working knowledge of operational excellence approaches, and particularly TPM 2 Win
- Experience in developing and implementing targeted training and development strategies in a production setting
- Experience in developing and implementing continuous improvement strategies in a production setting
Behavioural Competencies
- Demonstrate strong leadership skills, including the ability to inspire and motivate teams, foster a positive work environment, and drive organizational performance, champion of diversity, equality and inclusivity practices
- Strong understanding of business principles and practices especially running a factory and manufacturing plant and ability to assess business risks
- Ability to develop and implement long-term goals and initiatives that align with the company’s vision and objectives
- Demonstrate a deep commitment to understanding and meeting customer needs
- Proficient in analysing complex data and information to make informed decisions demonstrating analytical skills by identifying issues and developing effective solutions
- Effectively communicating and presenting information, insights, and recommendations to diverse audiences through engaging and visually appealing presentations.
- Ability to employ logical reasoning and critical analysis to evaluate information and make sound decisions
- Continuously seek new opportunities to enhance KWAL products and service, embracing new technologies and methodologies to drive growth and maintain a competitive edge
- Ability to support the professional growth of employees through guidance and feedback
- Demonstrate the ability to negotiate terms, agreements, and contracts with clients, partners, and vendors
- Demonstrate conflict management and crisis resolution skills
- Demonstrate resilient, agility, ability to work under pressure with high integrity
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