Engineering Lead - Cocoa Bean Process Plant

Order Ref:                    1214

Position Title:              Engineering Lead - Cocoa Bean Process Plant

Duration:                      Contract

Location:                      Chirk, Wales

About the Role:

• Our Client 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 ensure engineering readiness at all times.

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 setting.

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.