Assistant Manager - Quality & Lean

About Emirates Global Aluminium

Emirates Global Aluminium is the world’s biggest ‘premium aluminium’ producer and the largest industrial company in the United Arab Emirates outside the oil and gas industry.  EGA is an integrated aluminium producer, with operations on four continents from bauxite mining to the production of cast primary aluminium and recycling. EGA employs over 7,000 of these people including more than 1,200 UAE Nationals. EGA operates aluminium smelters in Jebel Ali and Al Taweelah in the United Arab Emirates, an alumina refinery in Al Taweelah, a bauxite mine and associated export facilities in the Republic of Guinea, a speciality foundry in high strength recycled aluminium in Germany, and a recycling plant in the United States.

JOB PURPOSE:

    To serve as a change agent, developing, coordinating, facilitating and leading continuous improvement projects under the umbrella of Lean Manufacturing and Six Sigma for Company Sites through Lean & Quality Engineers.
    Responsible for coaching and mentoring on Lean & Six Sigma tools and methodologies, coaching project champions and process owners, and developing future leaders of Lean Manufacturing .
    Responsible for completing productivity projects assigned from Higher Management and Manager Lean & Business Transformation
    Contribute to the enhancement of Business efficiencies and effectiveness of the site by developing and implementing world class strategies and advising and coordinating with  Maintenance, Finance, Operation, process control, laboratory, other service departments and Senior Management and their staff the implementation of the outcomes of Lean Manufacturing systems, techniques and other comprehensive range of Industrial Engineering (IE) projects.
    Develop/Customize and Manages the site-specific implementation, maintenance and improvement of the Lean Manufacturing & Business Transformation.

 KEY ACCOUNTABILITIES:
Lean Manufacturing Strategy
    Leads and delivers the company’s Lean and Six Sigma strategy that will ensure business improvements and significant business impact (in terms of process improvement and cost savings) across Company Site.
    Monitors, reviews and resolves deviations & reports on the actual performance/expenditure against the strategy or strategic objectives to ensure that all the area objectives are achieved within the approved budgets.
Business Transformation Projects
•    Facilitate, identify and recommend the improvement projects/proposals / Tamayaz project to the areas to support the annual objectives as defined by the management.
     Assist areas in preparing the annual plan for potential improvement areas, kaizen events, projects / Tamayaz and coordinates the projects defined within the agreed Lean Manufacturing journey to arrive at recommendations/action plans, after thorough analysis & comparison of alternative options, for improvement and the beneficial consequences of their implementation.
Tracking and Follow up of Business Transformation Performance and Projects
    Drives visibility and awareness of Lean Manufacturing, by tracking continuous improvement status, cost savings, training certifications, Lean project / Tamayaz status etc, and communicates Lean Manufacturing activities and successes.
Analysis and Prioritization
    Aligns the company’s Lean manufacturing and Six Sigma Guiding Principles deployment with department strategy and prioritizes projects accordingly, ensuring full deployment for driving Lean leadership throughout the company.  
Mentoring / Coaching of Lean and Quality Team and Areas
    Acts as a mentor and coach to Area managers and Sr. Lean & Quality engineers thereby increasing confidence and commitment to drive sustainable continuous improvement in the organization.
    Leads complex high-visibility lean projects across Operational departments, providing competency, leadership and direction to the department manager and employees.
Lean Manufacturing Tools implementation
    Manages Lean project portfolios, conducts Kaizen events, leads Black/Green Belt training with a dynamic presentation style demonstrating the ability to translate concepts into practical application, and provide focused mentoring and coaching.
Process Management
    Works with Area process managers to develop, analyse and implement improved cross functional systems and processes that guarantee smooth flow of product within the value stream.
    Develops Visual Management Systems to drive daily operations to continuously improve cost, quality and delivery.
EGA Lean Manufacturing & Business Transformation KPIs and tracking
Supports the execution of the company’s Lean Manufacturing & Business Transformation strategy at EGA Site to attain specific business improvement objectives consistent with the business strategy and the deployment of Lean Manufacturing principles.
Productivity Projects
    Timely completion of all productivity projects identified internally or given by Senior Management, with highest level of satisfaction level.
Training and Awareness
    Partners with, trains and coaches employees in the Lean and Six Sigma methodology.

 AUTHORITY/ DECISION MAKING:
    Problem Solving and root cause analysis is one of their critical tasks.
    Thoroughly work with the PDCA (Plan – Do – Check – Act) continuous improvement cycle. Has accountability to modify any implementation if not following the Lean Manufacturing Principles. Any decision that prevents the system to fail can be taken by the job Holder, whilst remaining within the scope of their responsibility.
    The job holder works independently and keeps the Departmental Management updated and consults in the area of decision making, financials, approvals, signing of contracts.

QUALIFICATIONS & SKILLS:
Minimum Qualifications:

    Recognised Bachelor’s Degree in Engineering with an accredited & internationally recognised professional certification. (Chemical, Industrial or Mechanical preferred) or a recognised Bachelor’s Degree in Science

    Lean Six Sigma Black Belt Certification.

Minimum Experience:

    At least 6 years’ experience in Lean Management preferably within the aluminium smelter, alumina refinery or heavy manufacturing industries OR accredited experience in Lean Manufacturing environment (at least 10 years). 

Skills:

    Experience teaching Lean and/or Six Sigma and mentoring projects is preferred.
    Thorough knowledge of Lean Manufacturing system.
    Strong Leadership and Management Skills. 
    Excellent in influencing skills.
    Ability to organize as well as to carry out tasks through to completion. 
    Excellent communicator. 
    Excellent written and spoken English and proven ability in the writing of procedures. 
    Excellent interpersonal and customer focused skills. 
    Excellent time management and priority setting skills.