The Process Engineer role is critical to the development of our factories to World Class, which means zero defects, zero waste and zero losses. She/he will apply extensively the full range of Focussed and Quality Improvement methods and tools to counter losses identified in the areas of Safety, Quality, Cost Deployment, Customer Service and Logistics. The Cost Deployment pillar will be populated with data built up through application of the Managing Manufacturing Performance Code, which is key to ensuring focus on key losses.
Working directly with the line crews on a daily basis the Process Engineer also acts as the technical trainer for line teams and provides coaching in phenomena identification, root cause analysis and the establishment of counter-measures.
The Process Engineer is responsible for the validation of all process improvements and the establishment of revised basic conditions on the line. A core deliverable is eliminate losses and wastes and increase the stability of the line to support the transition of traditional line teams to semi-autonomous teams.
Key Skills and Competencies
- Consumer & Customer Focus. Building world class factories will eliminate losses and ensure that we do not pass on the cost of inefficiencies to our customers and consumers.
- Bias for Action. By providing consistent and near real time information, decisions can be taken quickly which leverage our resources.
- Building Talent & Teams. Our vision is to move to semi-autonomous teams and we require process engineer’s with a passion for achieving results through great teamwork, an ability to teach new tools and methodologies and ensuring that you and your colleagues are fully aligned, and drawing on one another’s strengths.
- Accountability & Responsibility. Taking responsibility for building your team’s performance and sharing your best interventions to help support other lines’ in their improvements.
- Growth Mindset. By building world class factories we will become more competitive in the market place and set the standards to which others aspire.
- UMS. Apply the full set of UMS methods and tools to identify root causes, define countermeasures and validate their effectiveness; mastery of AM, PM, Q and FI tools and processes. Establish standards to support line operators sustain new basic conditions.
- Process and Organisational Design. Leverage technical knowledge and a systems approach to ensure factory lines and processes are optimally resourced (e.g. manpower ratios are efficient and sustainable).
- Analytical capability. Collect and analyse complex data to penetrate problems’ phenomena and understand root causes.
- Eliminate Waste and Loss according to the WCM prioritization process using AM, PM, FI and QC pillar tools and methodologies.
- Create Technical Standards to ensure process stability on the line.
- Train line crews on technical standards and restoration of basic conditions (Stability sustainability).
- Identify and extend good practice to other lines.
- Application and accuracy of MMP Code data.
Key Performance Indicators (as driven by Cost Deployment Analysis)
- Benefit/Cost Ratio (a. For projects led b. Measured against salary).
- Level of Savings (by saving type/category).
- Productivity (Man-hour/ton-FTE/ton).
- Length of changeover.
- Number of minor stops.
- Total Recordable Frequency Rate (TRFR).
- Quality D Incident.
- Waste Reduction.
Role Requirements on Initiation of Post:
- Able to visualize clearly what the ideal production system is;
- Able to clearly understand operating principles and establish correct operating standards;
- Able to present findings and rationales clearly so that whole factory team can understand;
- Able to make logical decisions based on data;
- Possess challenging and pioneering spirit.
Post Graduate level education; Mechanical, Chemical or Electrical Engineering.
There are 2 routes available for this role:
- Direct Entry role for post graduates engineers. Must demonstrate a flair for improvement engineering and coaching.
- Developmental role for technicians and First Line Managers (formally Supervisors). Must demonstrate a strong technical knowledge across all the site’s processes and lines. Must possess strong engineering leadership credentials with a proven ability to eliminate loss and waste on significant projects (normally above €1m).
- Experience in statistics and process control tools.
- Experience in AM, PM, Quality and FI tools and processes
Unilever is an organisation committed to equity, inclusion and diversity to drive our business results and create a better future, every day, for our diverse employees, global consumers, partners, and communities. We believe a diverse workforce allows us to match our growth ambitions and drive inclusion across the business. At Unilever we are interested in every individual bringing their ‘Whole Self’ to work and this includes you! Thus if you require any support or access requirements, we encourage you to advise us at the time of your application so that we can support you through your recruitment journey.