Job Description:
The Filling Supervisor plays a key role in reaching the HSSE, Quality, OTIF, PSA, RFT OEE targets in LOBP and GMP filling lines , working closely with planning, maintenance, laboratory and logistics departments and bulk operations team. Additionally, HSSE and Quality focal points are key stakeholders of this role.
Purpose
Supervise all packed filling (packaging) of Lubricants and greases in accordance with LQS, IATF and ISO requirements and according to the Plan set by the Production Planners whilst meeting HSSE, Security and Environmental targets.
Asset integrity & process safety and stakeholder & people management are the most crucial aspects of this role.
Dimensions
Size of the team: Manages 26 staff (1 Filling team leader, 25 operators)
# of Shifts : 2
KPIs : PSA, RFT, OTIF, OEE, Margin Leakage (MCV), Flush, Bulk Stock Gain&Loss
HSSE: Goal zero
Quality: No Major Customer Complaint
Contribute in delivering OPEX budget target
Principle Accountabilities
- Ensure all GMP and LOBP filling is carried out in accordance with roles described in GSAP/Streamline.
- Ensure All Filling Lines (Packaging, Capping, Labelling, transfer systems (e.g. conveyor, AGVs, forklift movements), de-palletizing, palletizing, wrapping, pigging, flushing, sampling, hose exchange) operations are performed in accordance with the Plan (set by the Production Planner) and consistent with HSSE & Quality rules and regulations.
- Work with Maintenance Supervisors and project supervisors to ensure Filling and Associated Equipment's availability is maximized by providing high level of AI (Asset Integrity) and support to R&I process
- Works with the Laboratory to reduce reduction of flush and waste oils and closely monitor and improve RFT (Right First Time) results for Filling lines.
- Ensure all manufacturing units and Filling Machines work in a coordinated manner (amongst itself as well as planning) to achieve OTIF (on time in full) to customers at targeted levels and to achieve OEE (Overall Equipment Effectiveness) in Filling.
- Coach, train and lead all Filling and production Operators.
- Support Maintenance& Investments team and Bulk Operations& Projects team for CAPEX project implementations in and Filling areas and participate all execution works.
- Manage empty pack daily requirements communication with suppliers for Lubes and Greases.
- Manage label printing activities for Lubes and Greases.
- Support new packaging transitions with global stakeholders.
- Manage physical finished products, packed additives, packaging stock counts with related Supervisors
- Lead assessment and implementation of the proposals coming from plant idea box system and classify/RAM rate of PI/NM/Intervention reports.
- To develop, motivate and recognize own team to create world-class professionals with a winning team spirit.
- Manage all Filling operations efficiently within budget, in compliance with Quality & Environment management systems & HSSE requirements
- Ensure all manufacturing units and Filling Machines work in a coordinated manner (amongst itself as well as planning) to achieve OTIF (on time in full) to customers at targeted levels and to achieve OEE (Overall Equipment Effectiveness) in Filling.
- Minimize product working losses (write offs / downgraded product / flushing oils) & achieve targeted level of RFT (right first time) in Filling. This will enable better Margin Leakage results hence less amount of MCV (Material Consumption Variance)
- Keep raw materials and empty packs in good condition at all times, ready for usage by regularly checking the physical conditions and shelf lifes.
- Keep all plant hardware in good condition for the continuity of operations through optimizing requirements & frequency of maintenance activities in coordination with Maintenance & Investments Manager.
- Update Filling Plant specific SOPs (Standard Operating Procedure) when necessary and train the operators.
- Ensure all stocks are accurate in terms of physical count and book in system which will enable less stock gain/losses.
- Manage rework operations of Lubemixes and part drums into permitted products in line with LQS requirements.
- Lead oil spill teams according to emergency response plan.
- Fully compliant with ISO9001 Management Quality system, ISO27001 Information security management systems, IATF 16949 International Automotive Task Force, TS EN ISO 14001 Environmental Management System, ISO 10002 Complaint Handling and Customer Satisfaction Quality Management Systems, ISO 45001 Occupational Health and Safety Management Systems standards/procedures/work instruction. (c)
- Authority to stop production and filling operations in case of any quality problem.
- Act as Permit Authorizer (PA), Isolation Authorizer (IA) in e-PTW system for his/her responsible area
- Fully compliant with ISO9001& 450001 Management Quality system, ISO27001 Information security management systems, IATF 16949 International Automotive Task Force, TS EN ISO 14001 Environmental Management System, ISO 10002 Complaint Handling and Customer Satisfaction Quality Management standards/procedures/work instruction
Related to HSSE:
- Implement the HSSE Plans, Policies, Standards and Procedures according to the HSSE-MS.
- Ensure risks of HSSE related activities are reduced to ALARP.
- Ensure assets are safe guarded and controls are in place for people to operate safely.
- Provide adequate training for staff to develop competence.
- Promote HSE Golden Rules and Life Saving Rules.
Behavioral Accountabilities:
Enterprise First behaviours in compliance with Shell Group Business Principles and D&I policy, displaying HSSE & Quality/Environmental systems awareness.
Required Experience Qualification
The position requires professional qualification in any of these disciplines: mechanical or chemistry and wide experience operating plants. Experience handling Plant instruments is also required. Demonstrated evidence of Enterprise first values and behaviors will be taken into account during the selection process. Bachelor’s Degree in Engineering with good command of Turkish and English is required.
