Operations Manager

Job Description : OPERATIONS AND PPC MANAGER MALAYSIA a British owned and run, Malaysian based volume manufacturer of leather and fabric beds that supplies some of the leading brands within focused markets for retail and contract furniture Duties & Responsibilities: - Operations: Planning, Production & Control, Shipping, Stores and Purchasing - Initial aim: Plan the factory to be >20% more efficient (dept by dept) Planning - Plan all machines, manpower, manpower efficiency and process in detail. This includes online, offline, floaters and everyone being accounted for, documented and co-ordinated (this will link to payroll and reward). - Plan manpower demand for HR & shopfloor for now / mid / long term. - Plan to succeed considering acceptable failure/downtime. Plan to reduce acceptable failure/downtime. - Increase efficiency though planning process (product grouping / segregation, cellular and dedicated lines, process co-ordination/management, jigs, automation etc). - Work with different types of manufacture - connect / sofa / bases / cellular. - Review and establish ‘new’ or ‘revised’ benchmark timing. Might need auditing to see where we actually are. - Understand factory manufacture and be involved in time & motion so that planning clearly understands all planned process. - Review, plan and implement shopfloor automation. - Review, plan and implement planning/backflush/stores/purchasing office and process automation. Consider RPA or other. - Data capture -> seamless live data capture. - Shopfloor empowered planning data–> output, efficiency, downtime, output discipline/training, maintenance etc. - Focus on data for empowered action –> not data for the sake of data. - Automate data collection and decision making. - Audit data for fraud and discrepancy. - Assist to plan training needs to manpower plan. - Understand and plan the training school as a way for output, training, easy transition into BSSB & retention. - Oversea training of workers efficiency with production from a planning perspective. - Integrate planning with purchasing and stores so supply information is seamless and JIT. - Prepare production schedule and lead clerical support staff to accomplish production planning within agreed guidelines, timelines and applicable lead times. - Liaise with sales for orders delivery and jobs priority. - Check on PI/ PO are received from sales team and are properly verified as per agreed procedures. - Follow up with sales team for outstanding PO. - Discuss, agree and brief production management on planning reporting requirements. - Ensure production reports are received and are verified as per agreed procedure. - Follow up production reports requirements as necessary. Brief production management on production schedule requirements, production manpower allocation, discuss and assess issues and solutions to ensure output requirements are met. - Monitor production progress and adjust schedule as needed. - Receive Non-Conformance reports from QC department and follow up to ensure they are properly closed off. - Prepare monthly report on all issues that have affected production output. Circulate to department heads to take corrective actions and follow up appropriate corrective actions have been taken. - Monitor machine requirements, maintenance and machine down time and alert if action is required. - Follow up with R&D to ensure pre-production meetings are held and required documents are received on time and meet all compliance requirements. - Monitor re-engineering department to ensure that production sample pass off procedure is followed and issues are dealt with and appropriate responses from R&D for process and document changes are within agreed timelines. - Ensure any Production sample changes are communicated to production. - Monitor and guide MRP team operation, set KPI’s and review staff performance. - Coordinate with purchaser on materials arrival as per accepted lead times. Follow up materials issues. - Consider and propose appropriate and relevant production timings data collection system for each department. - Develop and lead a team to collect and analyse production timing data from all departments. - Liaise and lead with the piece rate implementation team that timing data collection and piece rate system is compatible. - Utilize and understand the factory. - Plan from machine and worker level up. - Balance factory. - Skill levels documented and workers utilized as per skill. - Review and approve with the team process and automation improvements and assess the impact. - Authorise and approve worker movement with production and HR in accordance to need. Shipping - Liaise with shipping department for optimum container booking. - Provide shipping reports. - Automate the process. Stores - Oversee all stores function with the HOD. - Ensure with the HOD proper warehouse operation. - Traceability. - Stock rotation. - Due care. - Documentation & accuracy. - Automate. - Reduce warehouse footprint; in particular mdf/lvl/carton box. - Space efficiency. Better warehouse layout - Reporting and reporting structure. - JIT. - Seamless communication flow. - Audit. Purchasing - Oversee all purchasing function with the HOD. - Ensure with the HOD proper purchasing operation. - Supplier balancing. - Risk strategy. - Documentation & accuracy. - Automate. - Reporting and reporting structure. - JIT. - Seamless communication flow. - Audit. Reporting - Cost per minute. - Piece rate output. - Downtime. - Efficiency and utilization levels (worker to factory). - All stores’ reports - All purchasing reports. - All shipping reports. - All warehouse reports. - Focus on reports for empowered action –> not reports for the sake of reports. - Live reports for empowered action – dashboard for all relevant parties (no need to ask – the reports are ready for their action). Others - Ensure all SOPs are in place, trained, understood and operational. - Streamline SOPs and automate SOPs. - Assist to improve corporate culture. - Assume other duties and responsibilities within your capabilities and which are allied with and compatible with this job scope, according to the requirements of the Directors. HR aspects - Lead, coach and mentor direct reporters and their subordinates to consistently deliver excellence in their undertaking as individuals and team players. - To ensure commitment and accountability at all levels by maintaining a cohesive organization motivated to meet and exceed expectations. - Set KPI, s for each group and team members. - To hire, discipline and terminate employees as required. - To lead by example at all times; through professional behaviour, integrity, commitment. Vision i. The operational hub of the business for ALL things incoming and outgoing to manufacture. ii. Smooth, efficient and automated. iii. Provider of democratized data for action. iv. Works as an integral team player. Initial requirement i. Learn and understand all relevant SOPs, JDs, org chart, factory operations, hr aspects, efficiency levels, current man min concept. ii. Understand staff and their daily work, process, SOPs and investigate immediate issues. iii. Get to grips with the impact of Covid on the business and what planning / purchasing / stores needs to do as the heart of the business to get the business back on track – when we get back. iv. Set goals, targets and timelines. v. Set this monthly for planning / purchasing / stores / warehouse. vi. Start taking over the planning department for 1st 3 months then move to purchasing and then stores. vii. Take over sofas planning (TBC). Key target i. Streamline and automate all office process. ii. Streamline and automate all production process. iii. Seamless communications (without communication). iv. Democratize planning and data for action. v. Decrease downtime, production risk, production variances. vi. Increase output within the current footprint. vii. Decrease production, stores and warehouse footprint. viii. Run a backed up and secure JIT. ix. Reduce handling / WIP.

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