The Rhyl operation accounts for c80% of the £25M turnover and would be the main focus for the role.  Manufacturing processes at Rhyl include CNC machining, (milling and turning), mild steel tube bending and forming, welding (manual and CNC), powder coating, mechanical assembly, testing, inspection and packing.

This is a new role for the business and as such there is limited lean practice established, the opportunity for improvement is vast.  Establishing lean is essential for driving efficiency to reduce product costs, to create the capacity required for the projected organic growth, and the cost-effective re-shoring and development of in-house capabilities.

Essential Duties

Essential duties will include, but not limited to the following:-

• Lead the seamless introduction of new products into the manufacturing environment, collaborating closely with cross-functional teams including design, R&D, and production.
• Develop existing manufacturing processes to improve efficiency through the elimination of waste and guided investment in new technology and new capabilities.
• Work closely with the R&D team to promote product designs for manufacturability, providing valuable input to ensure efficient and cost-effective production processes.
• Develop and maintain detailed project plans, outlining tasks, timelines, and resource requirements for new product introductions.
• Utilise lean manufacturing principles to streamline workflows, optimise resource allocation, and reduce waste across the production process.
• Review existing assets and equipment establishing a risk and suitability matrix, keeping abreast of relevant technology and innovation.
• Conduct time and motion studies to identify opportunities for process improvement and implement changes to enhance efficiency.
• Collaborate with production teams to design and implement standardised work procedures, ensuring consistency and adherence to quality standards.
• Lead root cause analysis efforts for production issues, identifying systemic problems and implementing corrective and preventive actions.
• Drive the implementation of Six Sigma methodologies and other continuous improvement techniques to achieve operational excellence.
• Train production operators and technicians on new processes, equipment, and lean manufacturing principles.
• Participate in cross-functional teams to ensure the successful transfer of products from prototype to full-scale production.
• Collaborate with quality assurance to establish and maintain quality control processes for new and existing products.
• Develop and maintain accurate documentation, including process documentation, engineering change orders, and production reports.

Education & Experience

• Bachelor’s degree in Mechanical, Industrial, Manufacturing Engineering, or a related field (or equivalent experience).
• 10 years of experience in an engineering manufacturing environment, with a focus on new product introduction, process improvement and lean manufacturing.
• Proven track record of successfully launching new products into engineering manufacturing, meeting project deadlines and quality standards.
• Strong understanding of lean manufacturing principles, Six Sigma methodologies, and process optimisation techniques.
• Proficiency in using engineering software and tools for design (Solid Works), CAM.
• Excellent problem-solving skills with an analytical and data-driven approach.
• Outstanding interpersonal and communication skills, capable of working collaboratively in cross-functional teams.
• Familiarity with regulatory and safety standards in manufacturing.
• Project management skills with the ability to manage complex projects and priorities.