Job Description
Siqalo Foods is seeking a Plant Controller to join their Spreads Division. The role will be based in Boksburg and report to the Production Shift Manager.
The Plant Controller is responsible for supporting the Production Shift Manager in driving compliance of quality systems and production management in the factory. Take full accountability of the shift in the absence of the Production Shift Manager and follow all required protocols or procedures including legislated and will be expected to support end-to-end processes and systems when required and is expected to carry-out any lawful duties assigned that might include supporting Co-mans. This position is based in the factory.
Ensure efficient and effective execution of tasks and activities within the shift from packaging to FG warehouse. Ensure the control and effective management of all quality and food safety, operational responsibilities within the shift predominantly in packaging and not limited to the entire plant facility, in line with set standards, targets and budgets. This position ensures full compliance to company policies and procedures, legislations, and business requirements of the Manufacturing team.
Duties & Responsibilities
Manufacturing and Operational Efficiency:
- Assist in managing operators on shift and ensures that production targets are met.
- Plan and coordinate with the planning team the planned volumes and the progress against production plan.
- Plan and ensure that raw and packaging materials in the plant are sufficient for the shift run and the next shift.
- Monitors blend calling and blending to ensure production lines are not affected by oil blend supply.
- Monitor the process and operational tasks to eliminate defects, waste and rework levels in production.
- Carry out manual preparation by addition and mixing of minor ingredients in the tank as per product formulation and quality standards.
- Operate and monitor SCADA systems to control, record, and optimise plant processes, ensuring parameters remain within specified limits.
- Ensure or conduct line throughput and line speed verifications daily and correct any deviations from set targets.
- Monitors OEE and production output at frequent intervals and take corrective actions when line falling behind the set plan during shift.
- Ensure that the packaging lines are changed to the required standards based on the product and size in line with the target time.
- Supports plant trials by ensuring all the necessary requirements and preparations are met fully.
- Review standard operating procedures or conditions and escalate for any update or corrective actions to be implemented.
- Lead rework in the plant and ensure that it is conducted in accordance with quality and food safety procedures and standards.
- Raise and log maintenance tags on Shopware.
- Be first in line to troubleshoot minor stops or process failures and resolve if possible before escalation. All breakdowns to be escalated in a timely manner if the issue is not resolved.
- Identify production problems and discuss possible solutions with Production Shift Manager and key team members.
- Constantly coach operators for effective team building and engagement.
- Capture timesheets, type of leaves on the approved system allocated by HR and ensure compliance to the biometric system.
- Fill in for operators when there is shortage of labour or relieve the lines when required.
Quality and Food Safety:
- Conduct online quality control for finished product CRQS.
- Support the manufacturing and maintenance team to ensure all food safety prerequisites including regulatory controls are met.
- Coordinate product on HOLD to ensure product is not released to trade.
- Conduct verifications and line clearance post changeover and any adverse event.
- Effectively manage adverse events and corrective actions on the shift.
- Ensures that GMP (Good manufacturing practices) encompassing food safety (HACCP) and sanitation standards are adhered to on the shift.
- Conduct quality and food safety audit requirements or corrective actions for the shift.
- Investigate non-conformances, document all findings and correctives actions taken on shift.
Environmental, Health and Safety:
- Complies and ensures that all health and safety rules are met and acts pro-actively by addressing any safety concerns which may be harmful to self or other employees.
- Issues permits to contractors and monitors that all safety requirements are adhered to, especially LOTOTO.
- Report all incidents that have occurred on the shift, conducts preliminary investigation and reporting.
- Ensures compliance of shift employees to safety standards, policies and procedures including legislated requirements.
Minimum Requirements
- Grade 12 or equivalent, A National Diploma in the Engineering or Operations field or relevant higher-level qualification.
- 2-3 years working experience at a supervisory level or proven exposure of working through people.
- Basic appreciation in the production field.
Knowledge and Skill:
- Working Knowledge of quality standards.
- Working Knowledge of quality standards.
- Basic appreciation in specific plant engineering skills.
- Working Knowledge of PC Skills (CRQS, SAP, QM, Shopware, SCADA, etc).
- Working knowledge of WCM principles (AM and Problem-Solving Skills).
- Working knowledge of OHS act and lockout procedures.
- Communication skills (verbal & written).
- Certification of competence in light rigging as appropriate.