Lean Project Manager/ Total Process Reliability

Company Name:
Dorigan + Associates
Lean Project Manager/Total Process Reliability Engineer(TPR)
Food Industry, Idaho

The Lean Project Manager/TPR position is responsible for creating a plan for and leading the Company's effort to reduce the cost of maintenance and downtime including overseeing the Total Process Reliability (TPR) improvement work of the Company's five Maintenance Managers; increasing the efficiency of production, packaging and warehousing operations, and improving materials, product logistics, and distribution through the application of Lean techniques; and providing engineering support to drive process/equipment improvements and give technical oversight for the development of standardized work.

Essential Duties and Responsibilities

Provide leadership, training, coaching, and oversight of the work of the Maintenance Managers' TPR improvement efforts in all plants. This would include leading them in setting TPR goals, establishing project plans, measuring performance, and an ongoing indirect reporting accountability. Provide TPR and Lean training to other individuals in the company, as well as facilitating and leading teams focused on improvement projects.

Utilize TPR to reduce the total cost of ownership of our equipment, reduce losses associated with equipment downtime, and improve the efficiency of maintenance activities.

Eliminate waste through the application of Lean practices throughout the enterprise and reduce wasted motion through the proper design of the work environment.

Provide engineering support for improving and troubleshooting process and equipment issues with both manufacturing and packaging processes.

Provide technical oversight in the development of standardized work and process specifications.

Improve the flow of products and materials by decreasing cycle times and eliminating bottlenecks. Conduct optimization and capacity analysis to drive improvement projects and support new business.

Must maintain the highest standards of data management by creating consistent, reliable data which will ensure accuracy and in turn, maximize the use of data and confidence in decision making.

All employees are responsible for upholding the principles of SQF 2000.

All employees are responsible for immediately reporting any food safety, food quality or plant security issues to management for appropriate action.

Other duties may be assigned.

Supervisory Responsibilities
This job generally has no direct supervisory responsibilities, but will have indirect supervision of the Maintenance Managers at each location.

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education and/or Experience
BS in an appropriate engineering discipline (Chemical, Mechanical, Manufacturing, Industrial, Agricultural) or equivalent and 10 years of experience, or a minimum of 15 years of experience in maintenance, process, and project work. Requires "hands-on" experience with maintenance, manufacturing operations, production and/or packaging machinery, project installations and startups, and continuous improvement of manufacturing lines.
Solid background in Total Process Reliability (TPR/TPM) with experience in:
Planning, scheduling, and kitting
Optimized preventive maintenance
Predictive maintenance including:
Vibration analysis
Infrared analysis
Oil analysis
Autonomous maintenance
Maintenance information systems
Solid background in Lean manufacturing with experience in:
Setting up and maintaining pull systems
Facilitating Kaizen events
Facilitating Value Stream Mapping sessions
Facilitating setup reduction events
Root cause problem analysis
Leading team-based improvement projects
Training and experience in the application of statistics in the maintenance and manufacturing environment including:
Optimization of preventive and predictive maintenance
The use of statistics in properly sizing finished goods and materials kanbans
Statistical process controls
Statistically designed experiments
Project management experience
Capital projects including:
Financial justification
Budget management
Timeline management

Language Skills
Ability to read, analyze, and interpret common scientific and technical journals, financial reports, and legal documents. Ability to respond to common inquiries or complaints from customers, regulatory agencies, or members of the business community. Ability to write speeches and articles for publication that conform to prescribed style and format. Ability to effectively present information to top management, public groups, and/or boards of directors.

Equipment Troubleshooting and Design Skills
Ability to troubleshoot chronic equipment failures, determine root causes, and implement equipment design changes to improve reliability and reduce maintenance costs.

Mathematical Skills
Ability to work with mathematical concepts such as probability and statistical inference, and fundamentals of plane and solid geometry and trigonometry. Ability to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.

Reasoning Ability
Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables.

Computer Skills
To perform this job successfully, an individual should have knowledge of Microsoft Office Suite, and preferably experience in TIMEX an Internet software; Adage Manufacturing software; and MS Project Management software.

Other Skills and Abilities
Emphasis and experience in advanced thermodynamics, fluid mechanics is a plus.

Other Qualifications
Must be able to travel within the BAF facilities and to outside customers and suppliers as requested. Travel at 10% to 25%, but may be higher for short periods.

Send Replies to
Connie Dorigan
Please send your Resume as a Word.doc with the title of the position in the subject line.

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