Engineering Lead - Cocoa Bean Process Plant

Order Ref:                    1214

Position Title:              Engineering Lead - Cocoa Bean Process Plant

Duration:                      Contract

Location:                      Chirk, Wales

About the Role

Our Client are seeking an experienced and driven Engineering Lead to oversee all engineering operations within our manufacturing process plant. This is a pivotal leadership role responsible for driving operational excellence, implementing lean manufacturing techniques, and transforming our maintenance strategy from a reactive model to a robust preventative and predictive maintenance programme. The successful candidate will lead a multidisciplinary engineering team and play a central role in improving plant reliability, efficiency, and safety.

Key Responsibilities

Engineering Leadership & Team Management

Lead, coach, and develop a team of engineers, technicians, and maintenance professionals across mechanical, electrical, and instrumentation disciplines. Set clear performance objectives, conduct regular reviews, and foster a culture of continuous improvement and accountability. Manage resource planning, shift coverage, and skills development to ensure optimal team capability. Act as the senior technical authority on-site, providing guidance on complex engineering challenges.

Lean Manufacturing Implementation

Champion the adoption and embedding of lean manufacturing principles across all engineering and maintenance activities. Lead the implementation of lean tools and methodologies including 5S, Kaizen, Value Stream Mapping, SMED, TPM (Total Productive Maintenance), and Root Cause Analysis (RCA). Identify and eliminate waste in engineering processes, reducing downtime, material costs, and inefficiencies. Establish and track KPIs aligned with lean objectives: GE (Global Efficiency inc. OEE), MTBF (Mean Time Between Failures), and MTTR (Mean Time to Repair). Facilitate cross-functional workshops and training sessions to build lean capability across the wider plant team.

Reactive to Preventative Maintenance Transformation

Develop and execute the strategic roadmap to transition the plant from reactive maintenance model to a structured preventative and predictive maintenance programme. Continue to implement a Computerised Maintenance Management System (SAP) to schedule, track, and optimise all maintenance activities. Develop condition-based monitoring techniques (e.g., vibration analysis, thermography, oil analysis) to predict equipment failures before they occur. Establish preventative maintenance schedules for all critical assets based on manufacturer recommendations, historical failure data, and risk assessments. Target a measurable reduction in unplanned downtime (e.g., 30-50% reduction within the first 18 months). Build a culture where maintenance is viewed as a value-adding function rather than a cost centre.

Plant Reliability & Continuous Improvement

Own the plant's asset management strategy, ensuring long-term reliability and lifecycle cost optimisation. Lead failure investigations and root cause analyses for significant breakdowns, implementing corrective and preventive actions. Drive capital expenditure (CapEx) projects for equipment upgrades, replacements, and process improvements. Collaborate with Production, Quality, Health & Safety, and Supply Chain teams to align engineering priorities with business objectives.

Compliance, Safety & Standards

Ensure all engineering activities comply with relevant health, safety, and environmental regulations and industry standards. Maintain up-to-date documentation including P&IDs, SOPs, risk assessments, and equipment records. Support internal and external audits and ensure engineering readiness at all times.

Required Qualifications & Experience:

A high level of experience in an engineering or maintenance leadership role within a manufacturing or process plant environment. Food industry experience is advantageous but not essential Proven track record of implementing lean manufacturing techniques (e.g., TPM, 5S, Kaizen, Value Stream Mapping). Demonstrated experience in transitioning maintenance strategies from reactive to preventative/predictive models. Strong knowledge of CMMS platforms (ideally., SAP). Experience managing multidisciplinary engineering teams in a 24/7 operational environment. Solid understanding of health and safety legislation and regulatory compliance in a manufacturing setting.

Desirable Qualifications:

Degree (or equivalent) in related Engineering field Lean Six Sigma certification (Green Belt or Black Belt). Experience with predictive maintenance technologies (vibration analysis, thermography, ultrasonic testing). Familiarity with Industry 4.0 concepts, including IoT-enabled monitoring and data-driven decision-making