Process Control Engineer

Directs the activities of a team/shift of production workers (semi-skilled and skilled) so that established production targets, including volume, cost and quality measures are safely met. Focuses on weekly activities, and giving daily assignments to a mid-large sized shift/team. Operations are of simple-mid level complexity (e.g. managing more than 1 line/area), normally requiring some more complicated machine set-ups.

Job purpose

This position is responsible for the first line of technical problem solving with product and processes.  They will support validations and follow-up reporting and are the key link between NPI process support and production in terms of receiving new products and accepting them for series production.  Clear and accurate escalation of technical process issues is a critical part of the role.

The position will control and lead optimisation of the process (eg. cycle time, Quality or downtime improvements).  They will actively participate in TPM and lean activities with the aim of stabilising and improving performance. This position will also take ownership for testing and other production related equipment in the area, ensuring working condition is maintained and regular calibrations are completed to agreed time schedules.

When required the position might be requested to assist with running and / or supervising the production area.  The role can be based in the production line or washcoat/coating area.

Principal accountabilities

• Provide immediate process support in the factory to minimise downtime and rejects. Ensure all process support issues are investigated and ensure improvement actions are identified, recorded, and implemented. Report incidents using defined system/documentation.
• Awareness of production plan at all times and current performance against it with respect to validations, new products and any unreleased products
• Participate in/lead trials, product validations and plant commissioning as required, contributing their processing and plant expertise to the task.
• Ownership of process and product related testing equipment in the production area to ensure it is kept in good working order and calibrations are completed to agreed schedules.
• Cover for the shift supervisor when requested
• Active involvement in TPM and lean activities
• Technical ability to be able to perform all operator duties within team as and when required.  Assist with any washcoat production activities as requested.
• Ensuring right quantity of PGM addition in right tank (Washcoat-PCE)
• Ensure all customer and internal Quality requirements are always met.
• Support the preparation activities required before, and participate during, internal and customer visits;
• Ensure all changes are managed through the change control process
• Keep SAP (or other ERP system) work orders up to date and ensure all transactions for stock control are kept up to date
• Ensure excellent, proactive communication with team and other departments
• Ensure safe working of yourself and look after other people’s safety
• Ensuring timely closure of any Quality or EHS incident in the shift.
• Carry out and Support CI project implementation works by providing technical setup.
• Accountability and Controlling of Production consumables
• He/she must support for Stock Count activity during the month end
• Monitors and communicates agreed KPIs, with clear communication and escalation at early stages of any issues.  Through a good understanding of the processes, propose improvement actions for all production related issues.
• Complete any other reasonably requested duties.
• He should continuously work with team to achieve Zero EHS Incident/Zero Defect/Zero Downtime/ in his Shift
• Conduct awareness sessions for operators on energy conservation & Train for Energy-efficient equipment usage.

Principal Responsibilities

• Down time analysis and action plan generation
• Leading Daily morning meeting, Shift Alignment Meeting, and weekly follow-up with teams
• Rejection PPM control
• Reporting Process Safety related Les
• Participate in Process Safety related RCA and deliver on defined Actions
• High standard of housekeeping and its standardization
• Meeting QMS & EHS target
• EHS Drives
• Collect data on energy use in production areas.

Principal Authorities

• To interrupt/stop the line in case EHS or Quality norms are deviating. 
• Manpower shifting in shift to meet day to day requirement
• Trouble shooting of EHS & Quality Issues
• To approve the leaves of Team Leaders & below.
• Revision of documents.
• Emergency controlling in shift
• LE Closure/Incident Closure
• Authorize to ask for PPE compliance
• Doing Root Cause Analysis, Containment Action and Suggestion on Corrective Actions to improve the Product Quality and EHS Conditions.

Scope

The PCE is responsible for shift support of technical product and process issues and technical decision making according to agreed protocols (E.g., washcoat decision flow charts, production line settings).  Active involvement in improvement and lean projects and responsible for production area testing equipment (maintenance and calibration).

Special factors

·Requires JM Clean Air product and process knowledge.

• Requires shift work
• Some international travel expected from time to time

Person specification

Qualifications/ knowledge/ experience

(Technical/ professional knowledge and skills competency)

• Degree level in technical discipline (eg. Mechanical, chemical engineering)-Essential
• 1 years’ experience working in production environment - Essential
• Specialist production training in JM Clean Air production environment (especially washcoat production) - Desirable
• Has worked on ERP system (SAP) - Essential
• Lean manufacturing and problem-solving skills - Essential
• Strong Microsoft Office and computer skills - Essential

Personal skills and key competencies

(including JM behavioural competencies)

• An ability to think on your feet and multi-task - Essential
• Great organisation skills - Desirable
• Strong analytical and problem-solving skills - Essential
• Ability to perform in an intense, fast paced and complex working environment to achieve targets that are given - Essential
• Excellent communicator - Essential
• Works well in teams - Essential
• A proactive and resourceful self-starter/ motivator with the ability to work without close direct supervision - Desirable

JM VALUES and OUR 3Cs

• Protecting people and the planet         
• Customer Focus
• Acting with integrity
• Collaboration
• Working together
• Create Value
• Innovating and improving       
• Owning what we do

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Johnson Matthey Plc is an equal opportunities employer and positively encourages applications from suitably qualified and eligible candidates regardless of sex, race, disability, age, sexual orientation, marriage or civil partnership, pregnancy or maternity, religion or belief.