Make Process Operator

Job description

Job Title: Make Plant Operator Business Function: Supply Chain Location: Port Sunlight JOB PURPOSE The role of Make Plant Operator is to deliver customer service requirements through maintaining the continued delivery of liquid materials to the Packing Hall as efficiently as possible. It is business critical for the Packing teams to receive the correct supply of materials in a timely manner, avoiding supply chain production issues. The Make Plant Operator takes the lead on ensuring excellent communication and team collaboration, maximising the use of any downtime to carry out improvements and/or supporting colleague capability and development. The Make Plant Operator supports the Shift Leader with operational decision-making and provides weekend production support, ensuring raw materials are safely picked, weighed, moved, delivered to the correct mixing location and returned to the correct storage location in line with site procedures. This includes supervising the safe and efficient offloading of bulk liquid and solid tankers, managing used raw material packaging, and maintaining accurate raw material stock records through correct SAP Warehouse Management transactions. RESPONSIBILITIES Safety Follow all site health, safety and environmental rules, policies and procedures at all times to protect yourself and others in the workplace. Demonstrate safe working behaviours every day, encouraging others to do the same and challenging unsafe acts or conditions when seen. Identify and report health, safety and environmental hazards, near misses and unsafe situations promptly, taking appropriate action to reduce risk where required. Lead regular safety, housekeeping and environmental inspections or audits and complete follow-up actions in a timely way for your work area. Ensure tasks are carried out in line with standard operating procedures and risk assessments and for which you are competent under your SOL. Support the deployment of training in your work area. Own procedure and risk assessment reviews for your area, amending or creating new procedures and risk assessments as required. Comply fully with all relevant site controls, permits and environmental requirements linked to the production area. Minimise waste and environmental impact through good housekeeping and the correct handling, segregation and disposal of waste and hazardous materials. Carry out emergency and spill response activities as required. Carry out the daily Tank Farm checklist during weekend production support, acting on findings and escalating risks or abnormalities promptly. Ensure tanker offloading is carried out in line with site safety procedures, including correct use of PPE, safe vehicle positioning, spill prevention, containment controls and emergency response requirements. Stop, make safe and escalate any tanker offloading activity where there is uncertainty, abnormality, damaged equipment, incorrect paperwork, material mismatch, spill risk or unsafe condition. Quality Follow all quality and hygiene standards, policies and procedures in the work area at all times, role modelling expected behaviours, supporting awareness and training, and challenging poor standards when observed. Manufacture, dispense and rework products and raw materials in line with approved quality procedures and standards to achieve product quality targets while minimising waste. Complete required quality testing, including analytical testing of incoming bulk raw materials before tanker offloading, and take immediate action to address any out-of-specification material, quality issue or abnormality. Maintain full traceability by completing SAP records, paperwork, batch information, tanker offloading records, quality checks and physical material movement records fully, accurately and on time from Goods Inwards through to finished batch. Verify incoming bulk tanker materials against delivery documentation and quality requirements before offloading, ensuring required sampling, testing and release checks are completed before transfer. Apply raw material warehouse and dispensing controls, including FIFO, quarantine requirements, approved weighing procedures and prevention of material errors, cross-contamination, overweighing, underweighing or incorrect issue to process. Ensure raw material containers are accurately labelled, replace illegible labels, and confirm drum tops, lids, seals and external surfaces are clean, intact, free from debris, drips or contamination, and suitable for storage or use. Understand quality critical control points, ensure they are monitored and maintained, and complete all required quality governance, cleaning and disinfection activities in the plant. Report, investigate and support resolution of quality non-conformances, using appropriate analysis and corrective actions to eliminate defects and prevent recurrence. Customer Service Carry out pre-start checks to ensure the area and equipment are clean and safe, in line with procedures. Start-up equipment safely in accordance with procedures. Shut-down equipment safely in line with procedures. Review and understand the weekly production plan, and work with the operations and planning team to keep it optimised. Ensure the area runs at optimal speed throughout. Regularly review performance against plan and take corrective action where needed. Anticipate and respond quickly to issues to minimise any impact on customer service. Complete changeovers and maintenance tasks in line with your competency and SOL (instructed level). Plan and execute work effectively with the line and planning teams to complete tasks on time, to standard, and with minimum changeover and run time. Escalate issues in a timely manner, where needed. Make up Carbopol solution to maintain stock in the day tank, including carrying out associated CIP and SIP activities as required and in line with site procedures. During weekend production support, coordinate raw material requirements with Make, Goods Inwards, Logistics and Planning teams to ensure materials are available in the right quantity, at the right time and in the right location. Ensure materials and IBCs are thoroughly inspected and processed onwards to the plant. Cost Operate equipment to minimise waste and product giveaway. Maximise the reuse of product rework wherever possible. Actively identify and lead improvements that reduce cost, waste and energy use. Carry out cycle counting, stock checks, stock adjustments and SAP reconciliation during weekend production support to maintain accurate stock records, full traceability and strong cost control. Run To Standard Understand and participate in the area Run to Standard master plan. Actively participate in the Run to Standard meetings and processes and provide board updates as required. 5S – Own, implement and audit 5S standards and actively improve workplace organisation, coaching others in the standard. AM - Own and carry out cleaning, inspection and lubrication tasks in work area to standard, as planned and constantly monitor equipment condition to anticipate breakdowns or any unplanned stoppages. AM – Maintain equipment settings (centrelines) through structured measure and adjust. AM – Train, develop and coach others in AM activities (CILs and Centrelines). AM – Actively participate in the equipment ownership programme, completing AM Steps 1 through to 4 in line with the training programme. PM – Pro-actively support the cell team in optimising maintenance schedules and improvements and carry out maintenance activities to correct standard in line with your competency and SOL (skilled level). PM - Provide breakdown information and support Engineers in analysis and counter measures. PM - Highlight any issues with equipment and own the issue to closure using the correct recording procedures (tag). PM – Ensure the work area is returned to original condition after maintenance activities. FI – Use performance measures to identify and prioritise losses, including minor stops and changeovers. FI - Record and classify losses accurately; manage and use loss data effectively. FI – Actively support the cell team to embed a “Fix forever” mentality with appropriate countermeasures. FI – Apply Unilever Problem Solving tools to spot and mitigate faults before they directly impact output or product quality. FI – Complete Kaizens to identify improvements in the work area. FI - Share knowledge with others in the skills required to resolve issues. FI - Reduce changeover times by the application of SMED (Changeover Improvement) techniques. FI – Create, catalogue and review procedures and risk assessments relevant to the work area, and support deployment and adherence. EEM – Support project teams on new equipment and product projects, ensuring vertical ramp-up and updates to all applicable procedures. EEM – Take part in MP and Pre-Delivery Inspection (PDI) workshops as required. Communication and Teamwork Maintain clear, accurate and timely communication across Make, Packing, Goods Inwards, Logistics, Planning, Quality, Engineering and shift teams. Keep logbooks, activity boards, SAP updates and operational records accurate and up to date. Complete effective shift handovers covering raw material movements, tanker activity, stock risks, quality status, delivery issues, safety concerns and required follow-up actions. Work with colleagues and the Line Manager to ensure cover for holidays, sickness, absenteeism, on-call requirements and other site-agreed arrangements. Escalate SAP transaction gaps, stock discrepancies, weighing or labelling issues, material identification concerns, suspected contamination, quality holds, spill risks and unsafe conditions through the appropriate operational route. Training and Development Complete all required training to the required standard and proactively ensure any refresher requirements are met. Actively participate in regular performance and skills assessments to ensure the update of performance and skills matrices. Take personal ownership to close performance and skills gaps identified by requesting, arranging and completing training activities. Seek feedback from others to further development of own skills and raise standards. Embrace training and development of the full team, supporting other team members where appropriate. When appropriate and relevant to your skillset, train new team members and complete the sign off of tasks. Where appropriate and relevant to your role and skillset, participate in emergency response training and refreshers. Change Identify improvement opportunities that benefit the work methods reducing effort, time and cost. Drive best practices in safety and quality assurance by implementing efficient processes and collaborating with colleagues. Participate in change initiatives, such as new installations and trials. Track successes and failures where needed to provide feedback on successes and challenges. Support team members to ensure smooth ramp-up and procedural changes for all. ALL ABOUT YOU Essential: GCSEs A-C or equivalent in Maths, English and Science. Basic level of computing skills including MS Office and Excel. Data interpretation and analysis. Organisation and prioritisation skills. Clear written and verbal communication skills. NVQ2 or equivalent in process skills. RTITB Counterbalance trained with License in date or other Material Handling Equipment relevant to the role. Desirable: Experience in a manufacturing or technical environment (FMCG) and ideally Making processes. Experience operating plant equipment including pumps, pipelines, valves, filter units, tank compressed-air systems and process control equipment. Knowledge of stock taking. Working knowledge and understanding of COSHH standards and Environmental standards ENV 14000. High level of safety awareness, including Process Safety, COMAH awareness, Manual Handling Assessments, Task Hazard Analysis and Safety Audits. Improvement initiatives and Project work. Practical creativity and manual dexterity. Previous SAP experience. The ideal candidate for this role displays the 4 Unilever behaviours in their work: Focus on what counts: Prioritise tasks that directly impact the safety, quality, performance and efficiency of the distribution process. Do whatever is within their control to understand the root cause of a problem and proactively take steps to fix it. Deliver with excellence: Strive for high standards in all aspect of work. Owning the responsibility to complete tasks in full and on time to maximise operational efficiency. Continuously look for ways to improve and suggest ways to remove non-value adding activities. Stay 3 steps ahead: Anticipate potential issues before they arise and prepare in advance for foreseeable activities. Be proactive in finding safer and faster ways of working to help the factory stay ahead of the competition. Be prepared for any disruptions, ensuring minimal downtime and smooth operations. Care deeply: Show genuine concern for the well-being of colleagues, consumers and customers. Respectfully calling out any behaviour that could put safety, quality or efficiency at risk. Be open to giving and receiving feedback enabling everyone to work at their best every day. By integrating these qualities, you not only embody the desired behaviours but also contribute to a more efficient, responsible, and supportive work environment. Contacts This role works closely with internal and external stakeholders to support the safe, accurate and reliable movement of raw materials from Goods Inwards through to Make operations, including: Make Operations, Logistics, Planning, Quality, Engineering, Safety, Stores, Warehouse and Distribution Centre teams. Supervisors, coordinators, shift teams, site management and support functions. Contractors, visitors, delivery drivers, hauliers, suppliers, Unilever supply units and third-party logistics partners. Internal material users and colleagues involved in production planning, stock control, quality testing and operational support. What We Offer Not only do we offer a competitive salary and pension scheme, we also offer an annual bonus, subsidised gym membership, a discounted staff shop and shares. You’ll have the opportunity to work directly with our renowned and exciting brands in a flexible and hybrid working environment. Whilst the role is advertised on a full-time basis, we would be happy to discuss possible flexible working options and what this may look like for you. We are a key advocate of wellbeing and offer a variety of support for our people including hubs, programmes and development opportunities. We strive to achieve a family-friendly and inclusive workplace and to, above all, create possibilities for all. Diversity at Unilever is about inclusion, embracing differences, creating possibilities and growing together for better business performance. We embrace diversity in our workforce. This means giving full and fair consideration to all applicants and continuing development of all employees regardless of age, disability, gender reassignment, race, religion or belief, sex, sexual orientation, marriage and civil partnership, and pregnancy and maternity. We are also more than happy to provide reasonable adjustments during our application and interview process to enable you to be present your best self. To find out more, including about our Employee Resource Groups, please click here Equity, Diversity & Inclusion at Unilever | Unilever . Recruitment Fraud Cyber criminals advertise fake job adverts with prestigious employers as a way of stealing information or even defrauding individuals out of money. In the most sophisticated cases, they will set up fake websites, which have a similar address to companies like Unilever. They even conduct fake telephone interviews and then offer candidates a role with the proviso they pay a fee for background checks or to cover work visa costs. These types of attacks are becoming more common as more people are looking for employment in the economic climate. How is Unilever tackling this? Many of Unilever’s recruitment sites publish a warning to candidates about recruitment fraud. The Cyber Security team also proactively scan for signs of people setting up fake Unilever sites and act to close them down. What can I do? If you become aware of potential recruitment fraud, spot fake Unilever recruitment adverts or fake LinkedIn profiles, report them via Una Live Chat. Unilever does not accept responsibility or liability for any candidates who are financially impacted by recruitment fraud. Your vigilance is key!