Quality and Health and Safety

Job Description – Process & Continuous Improvement Engineer

Timings: Monday-Thursday: 07:00-16.00, Fridays: 07:00-13.00 Reports to: Factory Manager Role Purpose Reporting directly to the Factory Manager, this role acts as their right-hand person on the factory floor. The focus is on understanding how work flows through the factory end-to-end, from goods-in to despatch, and making it safer, faster, more consistent and less wasteful. You will analyse processes, use data to find the root causes of problems, and lead practical improvements that stick. Quality and health and safety are built into how processes are designed and run, rather than checked at the end. Roles & Responsibilities

• Process & workflow analysis o Map and analyse end-to-end workflows from goods-in through production, finishing and despatch o Identify bottlenecks, waste, downtime and double-handling; carry out time studies, capacity and line-balancing analysis o Review factory layout, material flow and storage, and reduce scrap and waste (including better waste segregation)
• Continuous improvement o Lead improvement projects using Lean tools (e.g. 5S, SMED/changeover reduction, kanban, standard work) and structured problem-solving tools (e.g. DMAIC, SIPOC, FMEA, SPC) o Write and maintain clear standard operating procedures and work instructions, train operators in them, and keep the training matrix up to date o Build business cases for improvements, implement them, and measure the results o Support the introduction of new products and processes
• Data & performance o Use FactoryIQ and production data to track throughput, OEE, downtime, scrap and right-first-time performance o Develop FactoryIQ to improve data capture and traceability; audit and spot-check data accuracy o Produce regular KPI reporting for the Factory Manager with clear actions
• Quality o Design quality into processes with in-process checks for product splays/tolerances, printing on steel and labels, and banding/timbers o Ensure goods-in is receipted correctly and incoming material quality checks are carried out o Ensure measuring equipment is calibrated and measurement is repeatable and accurate o Investigate NCFs to root cause and drive corrective and preventive actions; maintain ISO accreditation requirements
• Health & safety o Build safe systems of work, risk assessments and ergonomics into process design and change o Promote a positive safety culture and support health and safety training
• Machinery & tooling o Monitor machinery and tooling condition; work with maintenance on preventive maintenance and reducing breakdowns o Appraise new machinery investments (including ROI) and support their specification, installation and commissioning
• Supporting the Factory Manager o Act as the Factory Manager’s right-hand person and deputise in their absence o Work closely with the Operations on planning and scheduling o Coach and engage team leaders and operators in problem-solving and improvement The above list is not exhaustive. The role may require other general duties not mentioned here.

Requirements

• Manufacturing, mechanical, industrial or production (or equivalent) practical experience;
• Proven experience in a process, manufacturing, industrial or continuous improvement engineering role in a manufacturing environment (steel/metal processing desirable);
• Practical, hands-on experience of Lean tools; Six Sigma Green Belt or similar desirable;
• Strongly analytical and comfortable working with data; advanced Excel skills; experience of MES/ERP systems (FactoryIQ an advantage);
• Working knowledge of ISO 9001 and UK health and safety requirements; IOSH Managing Safely or NEBOSH desirable;
• Visible on the shop floor, with the ability to influence people at all levels and lead change;
• Excellent written and verbal communication skills, with high attention to detail;
• IT proficient (Microsoft Office suite)