Production: Unit Asset Optimizer (AO)

Overview

The Washington Works site currently has an opportunity available for an Asset Optimizer. This member of the production leadership team will collaborate with supply chain (Planner / S&OP / Scheduler), operations (DELs), and maintenance (Scheduler & Planner) to develop and execute a unit production plan that will maximize asset utilization, labor efficiency, and achieve unit cost objectives while also meeting market demand.  This role is accountable for meeting business objectives and ensuring operational excellence.   

• Production Schedule Execution (Actual vs. Plan)
• Financial – Monthly & Annual Budget Performance (Actual vs. AOP)
• Controllable Cost Per Unit ($/Kg.)
• OEE% vs. Goal
• Product Yield (FPFQ Production)
• Blocked Stock Objectives (Generation & Inventory)
• Achieve Annual Operational Excellence Objectives (Continuous Improvement)

Responsibilities

• Responsible for meeting unit's production plan by establishing clear priorities and ensuring an effective communication process with operations and maintenance leadership to assist their decisions related to asset availability and/or labor utilization.
• Ensure that all resources (labor, equipment and materials) are available to meet production schedule.
• Manages the timeline and decisions related to planned start-up/shutdown of assets and any production schedule changes attributed to unplanned downtime.
• Creates and leads employee development plans for respective team members.
• Manage all reliability escalations and reliability action items to identify emerging maintenance issues and/or implement proactive steps to mitigate business impact.
• Constant collaboration with S&OP, Supply Chain, Operations, Maintenance, & Reliability to provide the unit with a clear operating plan (expectations) and regular status updates on performance versus plan.
• Oversee the integration, communication, and execution of daily maintenance & production schedules. 
• Based on business needs, ensures that the maintenance scheduling process (planned & reactive) aligns with operational plans.
• Assists with the development of scope, timeline, & communication plan for unit TARs / shutdowns and monitors daily progress completion per plan by maintenance & project personnel.
• Accepts the Unit's demand forecast from Supply Chain and works with the Unit Asset Lead (Maintenance) & Unit DELs (Operations) to develop the  unit's evergreen operations plan focused on maximizing throughput & achieving cost per unit objectives.  
• Works closely with Maintenance Scheduler on defining planned PM schedule on assets and executing opportunistic maintenance activities when unplanned downtime on assets occurs to maximize throughput.
• Responsible for reviewing and managing the POLY Quality Release Test Data in efforts of identifying gaps and improving first pass quality through the escalation process and/or assigning QN3s.
• Responsible for UD (usage decision) Assignment for ALL unit production (POLY in-process, PACK in-process, & PACK FG) to maximize product FPFQ, ensure customer satisfaction, optimize the efficiency of product/process flow.
• Accountable for maximizing product yield by identifying opportunities to reclassify materials when appropriate to reduce blocked stock generation and updating the NRM rework spreadsheet as needed.
• Perform monthly Yield & Blocked Stock Data Analysis to identify "bad actors" and lead Operational Learning Teams in collaboration with DELs to achieve business results.
• Accountable for the development and execution of Autoclave’s monthly polymerization and packaging production schedules.
• Accountable for managing the Unit Operational KPIs (establishing, updating, communicating/distribution, & the escalation of variances to performance goals).
• Accountable for raw material availability, warehouse inventory & housekeeping standards, establishing and adjusting min./max safety stocks, execution of milk runs for RMs and packaging supplies, and the direct line of leadership communication with external warehousing to ensure proper inventory levels and material transfers.
• Identifies emerging supply issues and appropriately manage inventories.
• Identifies quality issues with raw materials and addresses with purchasing or supplier.

Qualifications

Required qualifications for this role: 

• HS Diploma or equivalent.
• SAP experience.
• Manufacturing experience related to production & maintenance scheduling processes.
• Experience motivating, leading and developing teams to achieve core principles.
• Drives engagement and possesses effective communication skills (verbal and written).
• Advanced computer and software experience.
• Capacity to solve problems to ensure business needs are met.
• Critical thinking, RCA knowledge, and the capability to prioritize and be decisive.

Preferred qualifications for this role: 

• Advanced Data Analysis.
• LEAN certification.
• Bachelor’s degree.
• Advanced data management and report writing skills.