Process Lead

2 weeks ago

Leicester, Leicester, United Kingdom PepsiCo Full time

Overview

Main Purpose

To drive a change to continuously improve performance and skills, which include the following:

  • To eliminate process losses on equipment or areas, and to drive standards and problem-solving
    processes.
  • To transfer knowledge to the line teams, and to ensure the proper level of skills and qualification
    successfully deploy the loss elimination skills needed for the line to deliver the line and team goals.
  • To ensure the lines are not underperforming due to the lack of technical process capability or
    knowledge.
  • To provide coaching, teaching, and assessment of problem-solving mechanisms.
  • To promote reapplication of approaches across the site and the network.
  • To ensure alignment with both the line lead and maintenance lead, supporting the training and
    development of equipment / process / area / system owners.
Responsibilities

The role of the process lead is to eliminate process losses on equipment or areas, to support the line team to create process standards, and to coach on using standard tools to perform problem solving. The process lead is responsible for implementing and/or maintaining, and continuously improving, the daily management systems (DMSs) they own in their area, typically the centerline (CL) and changeover (CO) DMSs.

Results

  • Improved product quality measures, e.g., product or package defects, waste, and consumer complaints.
  • Improved overall equipment effectiveness (OEE) / process reliability (PR).
  • Improved process failures, e.g., extended time unplanned stops of the equipment.
  • Improved process controls, including the use and development of centerlines (CLs).
  • Improved changeover (CO) time and startup quality.
  • Driving the use of standards / one point lessons (OPLs) / rapid changeovers (RCOs).

Accountabilities

Leadership

  • Actively participating in line daily direction setting (DDS) meetings and in the execution of the daily plan, including reporting on the following results for the previous 24 hours:
    • Centerline (CL) completion and compliance.
    • Changeover (CO) adherence to plan and critiques.

Planning and maintaining continuous improvement (CI)

  • Identifying, prioritizing, and eliminating process losses.
  • Building the process capability and control.
  • Providing feedback to design (FtD) and leading smart standardization deployment.
  • Defining equipment standards.
  • Leading the change management (CM) and validation processes.
  • Leading and building the capability of process failure technical troubleshooting.
  • Leading the process of benchmarking and reapplication.
  • Collaborating with line leads and equipment owners (EOs) to develop new standards.

Owning line tasks

  • Designing, implementing, and maintaining systems to collect and analyze data for critical product and process parameters.
  • Using this data to identify process losses.
  • Working with line management to prioritize improvement opportunities.
  • Eliminating or reducing (prioritized) losses through making process or work system changes
  • Participating in the daily direction setting (DDS) process – report results, flag issues, and request
    resources.
  • Owning critical daily management systems (DMSs), e.g., centerlining (Run-to-Target [RTT])
  • Using reliability engineering (RE) and data analysis tools to drive centerlining and loss elimination
  • Standardizing equipment and work processes; owning the change management (CM) system for a designated process; updating process control strategies and operating procedures, as changes occur.
  • Sharing and reapplying learnings across processes, modules, and plants.
  • Preparing and giving training on process / equipment changes.
  • Developing him/herself through participating in corporate and external training.
  • Taking part in planned stops and rapid changeovers (RCOs) flowing to the line, as needed.
  • Standardizing and improving rapid changeovers (RCOs).

Other expectations

  • Spend 80% of the time on the floor.
  • Become a technical expert for a designated process.
  • Qualify in all basic operating roles.
  • Coach and collaborate with the line teams, and with site and regional equipment or process owners.
Qualifications

Minimum of five years of experience in a Leadership Role at a site and has:

  • Basic integrated work system (IWS) / high performance organization (HPO) training.
  • Demonstrated strong interpersonal collaboration skills.
  • Effective communication skills at all levels of the organization.
  • Ability to present to small groups.
  • Strong technical skills, and ability to work with data and information.
  • Priority setting.
  • Strong communication / coaching / training skills.
  • Technical and practical equipment and tool skills.
  • Demonstrated ability to assimilate technical data to support recommendations.
  • Good experience of problem solving in the production area.
  • Familiarity with structured problem-solving tools.
  • Experience in using Microsoft Office, and specifically Excel or other analytical applications.
  • Shop Floor Credibility is important.
  • Active Listener.

Differentiating Competencies Required

Success in this role requires a unique and complex blend of technical, analytical, creative, business, project management and leadership skills comprising.

  • Ability to influence technicians, engineering resources and line leads, as required.
  • Ability to teach, coach, and develop others.
  • Have on-the-floor technical credibility with the people doing the work.
  • Have effective communication skills, including the ability to be an active listener, and also the ability to both positively confront and be assertive, when necessary.
  • Have a passion for the work, and the drive and ability to help others see the losses.
  • Be personally committed to the self-development required of the role.
  • Have an understanding of the equipment's processes for transforming the product.
  • Have experience in manufacturing, and the ability to understand the manufacturing process.
  • Possess a flexible mindset, e.g., a willingness to flow with the work, and to cover training and breaks, as required, to deliver the line key performance indicators (KPIs).
  • Be willing to actively participate in planned stops and changeovers (COs), flowing to the work as
    required.
  • Ability to use data and logic to problem-solve.
  • Ability to perform analysis of data.
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