Engineering Lead - Coca Bean Process in Chirk

About the Role:

• We are seeking an experienced and driven Engineering Lead to oversee all engineering operations within our manufacturing process plant.

• This is a pivotal leadership role responsible for driving operational excellence, implementing lean manufacturing techniques, and transforming our maintenance strategy from a reactive model to a robust preventative and predictive maintenance programme.

• The successful candidate will lead a multidisciplinary engineering team and play a central role in improving plant reliability, efficiency, and safety.

Key Responsibilities:

Engineering Leadership & Team Management:

• Lead, coach, and develop a team of engineers, technicians, and maintenance professionals across mechanical, electrical, and instrumentation disciplines.

• Set clear performance objectives, conduct regular reviews, and foster a culture of continuous improvement and accountability.

• Manage resource planning, shift coverage, and skills development to ensure optimal team capability.

• Act as the senior technical authority on site, providing guidance on complex engineering challenges.

Lean Manufacturing Implementation:

• Champion the adoption and embedding of lean manufacturing principles across all engineering and maintenance activities.

• Lead the implementation of lean tools and methodologies including 5S, Kaizen, Value Stream Mapping, SMED, TPM (Total Productive Maintenance), and Root Cause Analysis (RCA).

• Identify and eliminate waste in engineering processes, reducing downtime, material costs, and inefficiencies.

• Establish and track KPIs aligned with lean objectives: GE (Global Efficiency inc OEE), MTBF (Mean Time Between Failures), and MTTR (Mean Time to Repair).

• Facilitate cross-functional workshops and training sessions to build lean capability across the wider plant team.

Reactive to Preventative Maintenance Transformation:

• Develop and execute the strategic roadmap to transition the plant from reactive maintenance model to a structured preventative and predictive maintenance programme.

• Continue to implement a Computerised Maintenance Management System (SAP) to schedule, track, and optimise all maintenance activities.

• Develop condition-based monitoring techniques (e.g., vibration analysis, thermography, oil analysis) to predict equipment failures before they occur.

• Establish preventative maintenance schedules for all critical assets based on manufacturer recommendations, historical failure data, and risk assessments.

• Target a measurable reduction in unplanned downtime (e.g., 30–50% reduction within the first 18 months).

• Build a culture where maintenance is viewed as a value-adding function rather than a cost centre.

Plant Reliability & Continuous Improvement:

• Own the plant's asset management strategy, ensuring long‑term reliability and lifecycle cost optimisation.

• Lead failure investigations and root cause analyses for significant breakdowns, implementing corrective and preventive actions.

• Drive capital expenditure (CapEx) projects for equipment upgrades, replacements, and process improvements.

• Collaborate with Production, Quality, Health & Safety, and Supply Chain teams to align engineering priorities with business objectives.

Compliance, Safety & Standards:

• Ensure all engineering activities comply with relevant health, safety, and environmental regulations and industry standards.

• Maintain up‑to‑date documentation including P&IDs, SOPs, risk assessments, and equipment records.

• Support internal and external audits and always ensure engineering readiness.

Required Qualifications & Experience:

• A high level of experience in an engineering or maintenance leadership role within a manufacturing or process plant environment. Food industry experience is advantageous but not essential

• Proven track record of implementing lean manufacturing techniques (e.g., TPM, 5S, Kaizen, Value Stream Mapping).

• Demonstrated experience in transitioning maintenance strategies from reactive to preventative/predictive models.

• Strong knowledge of CMMS platforms (ideally., SAP).

• Experience managing multidisciplinary engineering teams in a 24/7 operational environment.

• Solid understanding of health and safety legislation and regulatory compliance in a manufacturing settings

Desirable Qualifications:

• Degree (or equivalent) in related Engineering field

• Lean Six Sigma certification (Green Belt or Black Belt).

• Experience with predictive maintenance technologies (vibration analysis, thermography, ultrasonic testing).

• Familiarity with Industry 4.0 concepts, including IoT-enabled monitoring and data-driven decision-making.

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