Process Production Team Lead Operator - Zentia
(2018-01)
Operator lead for a small team on 12-hour Continental shift pattern, providing day-to-day direction and support to maintain safe and effective production.
- Work both on line and from a control room environment using multiple PCs and PLC controls to monitor and manage the process.
- Operate a critical machine within the manufacturing process, ensuring consistent performance and reliable output.
- Responsible for safe working practices within the area, maintaining compliance with site procedures and standards.
- Run the area to schedule while maximising efficiency and keeping waste to a minimum.
- Host daily meetings reviewing the previous 24 hours of key KPIs, performance issues and priorities for the shift.
- Work closely with the engineering department to secure a quick response to breakdowns and minimise downtime.
- Manage supply to the process of the raw materials required to ensure enough stock is available and mixed to the correct consistencies to enable the smooth running of the line.
- If required to load materials by means of clamp and fork lift trucks and hoists.
Production Co-Ordinator - Walkers Snack Foods
(2016-09 - 2018-12)
Co-ordinated production performance across 12-hour Continental shifts, balancing output, scheduled downtime, engineering activity and sanitation requirements.
- Provided leadership across the site KPI scorecard, with focus on waste, product service level, volume and operational efficiency.
- Worked closely with the engineering department during breakdowns to minimise downtime and restore production safely and efficiently.
- Led root cause analysis reviews for production issues lasting 90 minutes or more, supporting corrective action and continuous improvement.
- Facilitated three efficiency meetings per shift to review departmental performance, waste, machine efficiency, schedule adherence and key operational issues.
- Liaised with the production scheduler to manage ongoing issues affecting the production plan and adapt priorities as required.
- Supported Shift Operations Managers by conducting investigations, gathering information for disciplinary matters and acting as note taker in formal meetings.
- Managed machine audit activity across the shift to ensure checks were completed on time and standards were maintained.
- Escalated operational issues in line with procedure and maintained clear shift handovers with oncoming Co-ordinators.
- Held responsibility for zone standards including employee risk protection, consumer risk protection, safety, standard settings and improved product specification.
- Provided cover for the Shift Operations Manager when required.
- Received PepsiCo's top manufacturing honour and travelled to the company's New York headquarters to collect the award following implementation of a cost-saving improvement that diverted good product from waste back into rework, delivering an annual saving of £100,000.
- Took ownership of quality performance within area, contributing to a 12% reduction in customer complaints.
Advanced Operator/Site Expert Trainer - Walkers Snack Foods
(2009 - 2016)
Travelled to Johannesburg for a two week course in Extrusion Process and a three week course in the UK for Packaging. This involved in-depth classroom based training and learning how to deliver training materials to operators on site.
- Led a small team of seven operators to deliver the shift schedule while maintaining KPI targets for performance, waste and quality.
- Acted as the go-to expert across the snacks process and packaging areas, supporting multiple departments with technical and operational knowledge.
- Coached operators and technicians, trained new starters on line operations, and developed training materials and records for upload to a central system.
- Attended off-site meetings with other UK manufacturing sites to review KPI performance and share best practice.
- Actively identified opportunities to reduce waste, improve quality, lower customer complaints and increase efficiency across process and packaging.
- Performed internal and external Improved Product Specification audits and addressed score losses through corrective action.
- Facilitated one True Efficiency meeting and contributed to two others, providing clear feedback on production performance and operational priorities.
- Supported the transition of new equipment and required skills following a site closure, including travel to Wales over a four-week period.
Manufacturing Operator in both Process and Packaging - Walkers Snack Foods
(2003 - 2009)
From 2003-2006 worked in the Packaging hall doing weekend shifts of 12 hours each with equipment such as Woodman and TNA bag makers and Ishida multi head weighers and checkweighers. From 2006 moved into Extrusion Process working on single and twin screw extruders making products like Scampi Fries, Bacon Fries and Wotsits using equipment such as Florigo fryers, Planet ovens, mixers, Extruders and other peripheral equipment.
- Keeping efficiencies of machines and waste in line with site KPI's.
- Carry out fault diagnosis, repair or planned maintenance of equipment. This could involve stripping out of shafts and bearings, replacing belts, lubrication of bearings and chains or calibrations.
- Carry out changeovers and liaise with General Operators and Hygiene Operators for this to be done in a timely manner.
- Identify any Continuous Improvement possibilities.
- Conduct daily machine audits and implement solutions to any point losses.
Manufacturing Staff in Body shop Department - Nissan Motor Manufacturing
(2000-01 - 2003-04)
- Welding the engine compartments onto Almera and Micra by using portable Spot Welding Guns being supplied to the main production line from within the Body shop.
- Part of the 4 man Planned Maintenance squad, which involved the cleaning and maintenance of the main production line parts, robots and assembly jigs.
- Given the responsibility of training the temporary staff onto their new jobs and workstations.
