Resin Manufacturing Lead

Resin Manufacturing Lead

This role leads resin manufacture at Deeside. It carries no direct reports and holds full decision-making authority for resin once trained and signed off, working a days pattern with accountability for resin output, yield, and compliance around the clock on 24/7 plant.

RESPONSIBILITIES

• Holds full decision-making authority for resin manufacture once trained and signed off. Decisions on cook parameters, vessel allocation, batch sequencing, and batch release stand across all shifts. Shift Supervisors will manage resourcing.
• The enforcement of safe systems of work on the resin plant and holding operators accountable for their health and safety performance.
• The provision of safe equipment, safe working environment, and ensuring all employees/contractors working on resin are provided with and wear the appropriate personal protective equipment.
• Ensure that everyone working on resin is adequately informed, instructed, trained, and supervised to safely carry out the work for which they are engaged.
• Ensure a safe working environment, striving for zero recordable injuries in compliance with internal policies and external legislation, through the delivery of key enabling activities (e.g. Near Misses, Safety Observations, timely completion of actions). Ensure that safety and environmental incidents on resin are fully investigated and the appropriate countermeasures established.
• Own the process safety requirements for the resin reactors under lower tier COMAH, DSEAR, and ATEX. The basis of safety is maintained, safety critical equipment, and alarms are in date and functional, and any operation outside safe operating limits is stopped and escalated immediately.
• Ensure a lab cook is completed following every feedstock delivery and that the resulting ratio charge values are submitted to production before the next batch runs.
• Verify production is running to the current charge values through to the next delivery. Superseded values are withdrawn from the floor, and every change is briefed at handover.
• Check operating conditions against the process specification through the batch and challenge any drift.
• Carry out production cross checks against the batch record at every handover. Discrepancies are resolved or escalated the same day.
• Deliver plan to volume. Track actual resin output against plan daily, forecast shortfalls early, and put a recovery plan in front of the Production Manager before the gap is locked in.
• Monitor yield and scrap by batch and by reactor. Quantify the loss drivers, take corrective action where it sits inside the role, and put a costed case to the Production Manager where it does not.
• Confirm raw material availability and condition before a batch is scheduled. No batch starts on material that has not been checked for quantity, specification, age, and condition.
• Confirm vessel and reactor availability ahead of the plan. Capacity and tankage constraints are flagged to planning in advance of planned manufacture.
• Monitor operating standards on the resin plant and initiate any necessary changes to procedures, cook sheets, and set points.
• Manage batch documentation to reflect process instruction and enable adequate data recording for compliance and efficiency monitoring.
• Monitor and report OEE and downtime on the reactors, identify the causes, and initiate reductions.
• Release batches and complete them in Oracle Cloud ERP accurately and on time. Open batches are not carried past the end of shift.
• Raise, investigate, and close deviations, NCRs, and CAPAs for resin. Root cause is traced to process, equipment, material, training, or scheduling.
• Confirm personnel availability against the resin plan and agree crewing with the shift supervisors ahead of the schedule being issued. Unresolved gaps are escalated the same day.
• Deliver resin training against the competency matrix owned by the Production Manager. Identify gaps, schedule delivery with the shift supervisors, and confirm every operator is trained and signed off to the matrix before running a reactor unsupervised.
• Push ownership of routine checks, first-line troubleshooting, and data capture down to the operators running the reactors, so fewer day-to-day decisions come back to this role.
• Communicate resin status, risk, and performance to stakeholders. Daily on plan, exceptions, and constraints. Weekly on yield, scrap, volume, and open actions.
• The Resin Manufacturing Lead should bring critical issues to the Production Manager's attention and assist in providing solutions to those issues.
• Also, responsible for escalating and resolving issues quickly and efficiently in the absence of the Production Manager.
• Cover is provided in the absence of other Supervisors.
• Recommendations to plant, equipment, and working practices on the resin systems are developed, costed against yield or output benefit, and effectively communicated to management.
• Operators and shift teams are actively involved in the development and introduction of improvement initiatives on resin.
• Operators and shift teams are encouraged to understand the business needs and the decision-making behind them.
• Performs other duties as assigned