Senior Process Engineer

 At Eakin Healthcare we put our patient at the heart of everything we do.

Fifty years ago, it all started with one man’s mission: pharmacist, Tom George Eakin. He saw his patients struggling with leaking urostomy pouches and decided enough was enough. He got to work and formulated what would become the game-changing, eakin Cohesive® seal.

Fast forward to today, and we’re still keeping it in the family. We’ve grown a lot since then, both organically and through acquisitions. We now have a team of over 700 colleagues across three manufacturing sites and 12 sales and distribution centres. We’re making a difference in three therapeutic areas:

• Ostomy
• Respiratory
• Surgical

 We’re proud to export our innovative products to over 60 countries through a network of 40 distributors plus our own offices in Japan, The Netherlands, France, Germany, Belgium and Luxemburg.

We’re good at what we do – come and join us!

ABOUT THE ROLE

Reporting directly to the Engineering Manager this is an exciting opportunity to join a growing team, and work across various functions. Working in close partnership with Operations, Quality & Research and Development teams to ensure all production requirements are in place for all new products and continuously reviewing and improving our manufacturing systems within the Cardiff plant - implementing change where appropriate. This role is a partially hands on role and will suit an individual who can quickly build professional working relationships, work within a team and enjoy working to a high degree of autonomy.

KEY ACTIVITIES

Operational 

• Be the internal ‘Subject Matter Expert’ for our manufacturing Processes.
• Central to this core role is monitoring existing Processes ensuring they are operating to their designed efficiency and output, leading actions when there are any identified issues.
• Identifying how we can improve the efficiency and output of processes as part of our overall Continuous Improvement culture.
• Review existing manufacturing systems and select appropriate modern manufacturing techniques and implement to drive efficiency and quality improvement.
• Maintaining process maps & PFMEAs, regularly assess process controls throughout the manufacturing environment
• In accordance with internal change management, implement process improvements and keeping under review the effectiveness of changes.
• Liaise with Quality team to ensure technical specifications and process validations are in place in a timely manner in accordance with the Site Master Validation Plan.
• Advise and coordinate with Engineering Manager any new equipment, tooling etc required for new products or process improvements ensuring the lead times are considered against project plans for product launches.
• Work alongside the production team to identify skills required from production operators and develop these to achieve team goals.

Lean Manufacturing

• Development of lean manufacturing principles in key areas where deemed appropriate.
• Contribute to lean manufacturing systems, visual management & 5S.
• Maintain a continuous improvement register demonstrating business benefits

Group

• Liaise with other company sites within the Eakin Group to implement new techniques and processes common to all.
• Occasionally work on multi-site projects with the wider group operations engineering team.
• Collaborate on benchmarking & best practice sharing.

Other

• To adhere to the company’s Equal Opportunities policy and Dignity at work policy in all activities and to actively promote equality of opportunity wherever possible.
• To be responsible for your own health and safety and that of your colleagues, in accordance with the company’s’ Health and Safety policy.
• To adhere to the company’s Quality policy and Environmental policy.
• To undertake other duties as may be reasonably required.

KEY SKILLS

Essential

• A degree / HND or equivalent qualification in an engineering discipline.
• Applicants with a HNC will be considered if they have exceptional experience.
• Previous manufacturing experience in a similar role.
• Expert knowledge in continuous improvement methods to improve overall equipment effectiveness (OEE), quality, reduce cost, inefficiencies and waste.
• Have a proven track record as a process ‘subject matter expert’ with the technical depth to adapt this knowledge to new technologies.
• Hold a valid driving licence and able to travel.
• Good working knowledge of MS Excel .
• Able to use 2D CAD systems e.g. AutoCAD.

Desirable

• Knowledge of ISO 13485 quality systems or an equivalent highly regulated environment.
• Previous experience of improvement projects in Lean manufacturing tools, to demonstrate use of some of the following tools: lean six sigma, Kaizan, 5S, Standard work, Kanban and value stream mapping.
• Able to demonstrate a Working knowledge of electro-mechanical systems.
• Experience with Automation and robotic control systems.
• Experience of manual assembly production processes.
• Experience with injection moulding & tooling.
• Experience of project management.
• Six sigma green belt or above.

KEY WORKING RELATIONSHIPS

Internal

• Operations – supporting onsite manufacturing Processes ensuring they are delivering to their designed output and efficiency. Undertake Process Capability studies to ensure we have stable manufacturing processes.
• Quality – responsible for Process Validation to the site Validation Master Plan.
• R&D – to ensure all product development requirements are translated to manufacturing.
• Commercial team – through the NPD process ensure all manufacturing requirements are scoped out at an early stage.
• Procurement – to ensure availability of materials to meet key miles stones. Supporting the validation of any material changes.
• Key Manufacturing team members – to liaise with department supervisors to ensure skills analysis and training is actioned. Deal with any trouble shooting maintenance issues and ensure effectiveness of key process controls. Work in partnership with the team to support the attainment of production targets.
• Finance – To provide input to the costing model for new products.
• Group – Network with group colleagues for own personal development and sharing best practice.

External

• Contractors – Outsourcing relevant work, scope out ad hoc projects, source new tools, equipment etc.

ADDITIONAL INFORMATION 

• Provide input to the annual budgetary process and contribute to key budgetary decisions.
• Occasional Travel Requirements.

COMPETENCIES

Customer Focus
Building strong customer relationships and delivering customer-centric solutions.

Manages Complexity
Making sense of complex, high quantity, and sometimes contradictory information to effectively solve problems.

Resourcefulness
Securing and deploying resources effectively and efficiently.

Optimizes Work Processes
Knowing the most effective and efficient processes to get things done, with a focus on continuous improvement.

Builds Networks
Effectively building formal and informal relationship networks inside and outside the organization.

Persuades
Using compelling arguments to gain the support and commitment of others.

Instils Trust
Gaining the confidence and trust of others through honesty, integrity and authenticity.

Self-Development
Actively seeking new ways to grow and be challenged using both formal and informal development channels.