Site Manager

What is the primary purpose of this job? Describe the 5-6 main objectives of the job and the approximate % of time spent performing each objective.

Direct responsibility for manufacturing operations of high hazard (Category A), multi-business unit site (Decorative Paints and Performance Coatings) including engineering, project management, HSE, Logistics, production planning and operations excellence (Plant Capacity: 35 – 40 ML/ year in 3 shifts

1. Develop and drive the implementation of ISC plan to support Business Strategy and Corporate/ Regional goals in terms of HSE, Sustainability, Service, Quality, Costs warehousing and logistics and Productivity. Setting and achieving KPI targets to meet defined levels

2. Establish and sustain the culture of functional and operational excellence by developing and maintaining continuous improvement programmes and implementing best practices in the Integrated Supply Chain(Looking at both internal and outside world)

3. Ensure that HSE is fully integrated into the management of operations activities (covering manufacturing and non-manufacturing locations) and that Group policies are fully implemented, covering engineering and safety standards, behavioural safety, PSM and Life Saving Rules. Establish process to understand, look for and respond effectively to hazards in safety, security, health and environment, taking account of people, plant, community and procedures

4. Manage operations  budget process and control of manufacturing cost and significant capital investments, including site expansion plans to support business requirements

5. Coordinate activities of site operations team and work effectively with functional managers, Sales & Marketing and Technical Managers to meet agreed objectives

6. Ensure company’s non-management personnel policies are implemented and effective contact is maintained with Union members & staff for a peaceful IR environment

7. Liaise with relevant government departments (e.g. EPA, Labour, Explosives etc) to ensure smooth running of operations and ensure all Site rules and regulations are complied with

8. Responsible for engineering and maintenance of plant and regional warehouses ensuring these are maintained in good operating condition and in compliance with governmental regulations to ensure effective and economical operations

1. Develop individual team members and build an engaged team which collectively is capable of and fully involved in achieving the department objectives

10. To contribute to overall management of the company as a member of Executive Team and to appraise executive committee on matters, relating to ISC as well as playing a part in the local policy firming up as a member of the executive team .  As a senior manager, to support Akzo Nobel values and set an example through personal behavior

11. Look after the RM and FG warehousing performance and ensure that all KPIs of warehousing and logistics are met.

12. Control and improve the overall OLC and SCC of ISC for Pakistan. These in turn would be communicated at the regional level on a monthly basis.

13. Continuously strive to bring innovation and improvements in the working of warehousing and logistics both internal and external.

What decisions may the job holder make without first seeking approval from higher manager/supervisor?

The job holder has to take the following decisions, covering short/ medium and long term horizons, to effectively manage site operation:

1. Development and implementation of ISC objectives and plans, setting KPI targets and directing/ guiding operations team to deliver on commitments
2. Finalization of production plans to meet business requirements (Meet volume and WIP inventory targets, OTIF etc)
3. Implementation, monitoring and control of various HSE processes to ensure safety of plant and people
4. Preparation and control of OPEX budget, once it’s approved by all the relevant stakeholders (Local and Regional)
5. Identification of Capex needs/ requirements and execution of Capex plan
6. Setting up the processes and enabling culture to drive continuous improvement activities in the areas of safety, productivity, OEE and manufacturing cost
7. Carrying out organizational needs analysis (Covering changes in the structure of Operations department, roles and responsibilities), identifying changes and implementing those changes after seeking approval from Hub ISC Manager and Regional ISC Director
8. Development and execution of plans to enhance professional growth of people, in line with their aspiration, capability and potential (LTR)
9. Shortlisting and interviewing of  candidates for recruitment against the positions related to DR1 of Site Manager

Please give two examples of the typical challenges or problems the job holder faces in their daily work and what they must do to overcome them.

Challenge # 1

Based on the issues/ difficulties mentioned below, managing safe operation of site on a continued basis is the biggest challenge:

1. It’s a Medium hazard site where flammable and explosive nature raw materials (e.g. solvents, NC etc) are stored and used for manufacturing different types of paint products and coatings. Also, at this site, acrylic is manufactured which is again a hazardous process as it involves exothermic reaction
2. Complex production process – solvent and water borne products are manufactured under one roof without any isolation/ dedicated area
3. A very high percentage (Approx 70%, 140 Nos) of our workforce is agency, which is not highly skilled and requires constant supervision and skills development
4. Production process is batch and without any automation – lots of manual handling is required
5. Site is located in a remote Industrial area in Faisalabad. Managing workforce and mitigating attrition as well as ensuring that external agencies are manager properly for smooth running of operations.
6. High attrition on site due to its location. Continuously look for ways to ensure employee engagement and welfare. Also, work with HR to ensure that a bench strength of potential candidates is available for any possible turn over.

Challenge # 2

Drive continuous improvement in productivity, yield loss, product quality and fixed manufacturing cost performance , warehousing and outbound logistics despite reduction in sales volume and inflation