SUMMARY:
Production / Reworks Supervisor
POSITION INFO:
Qualifications
Duties / Requirements
- Confirm that all inventory for reworks tasks (scheduled, in progress and completed) is accurately captured and reflected on the SAP system.
- Check that Reworks inventory is managed optimally and that stock in inventory does not diminish below the minimum buffer levels.
- Maintain the administration of the packaging material inventory.
- Check that all inventory and raw materials, to accomplish the BOM’s set out in the
- Reworks daily schedule are assembled the day ahead of the Reworks daily and weekly (if possible) schedule date.
- Physically count the completed reworks, and have it allocated or moved to the relevant bin locations.
- Liaise closely with the Planning Team to ensure the projected reworks schedule is in line with Sales Forecasts in terms of SKUs (Item) and volume.
- Check that the Reworks buffers stock is optimal at all times.
- Acquire the Bill of Materials (BOM) planning information to be used when compiling
- the daily Reworks Schedule.
- Compile the daily, weekly and monthly schedule, based on priority of products that need to be reworked / repacked. The Reworks daily schedule will be verified two days ahead of the due date.
- Assign tasks to the Reworks team, manage the team’s productivity and ensure that tasks are completed within the scheduled times.
- Create an efficient (meet or exceed projected Reworks targets) production workflow
- (fulfilment line) for every Reworks team assigned to a task.
- Prioritise daily duties to ensure that preference is given to tasks marked as urgent from Sales, Planning and Management or if there is a confirmed order and picking slip.
- Allocate picking of inventory, against the BOM, to the Reach Truck Operator allocated to Reworks.
- Oversee and check the samples made by the team and take them to the Planning Department for approval. Planning must sign the paperwork on all items checked to ensure accuracy and correctness of the samples.
- Any issues with samples or packaging received from Planning, must be addressed
- and reported on email to the Planning Department and Warehouse Manager.
- Employees are responsible for housekeeping of the area. Supervisor will ensure that the Reworks Area is clean and well maintained at all times.
- Compile a daily, weekly and monthly Reworks Product Schedules, which will be used for a basis for production. This is the Model Stock report, were products and packaging must be above 80%.
- External Reworks tasks must have an ETA on completion, in respect of the Bill of Material (BOM) Process.
- Validate the daily Production Schedule two days ahead and update accordingly if required. E-mails must be sent on the reason for non-completion of BOMs.
- Check that all Reworks orders are waved on SAP.
- Based on the BOM Report, update or compile the Daily Scheduling clearly reflecting the tasks to be prioritised, on the planning board and maintained on completion, or add on of tasks.
- Print all BOMs for the Reworks Department to be processed as per the reworks daily schedule.
- Determine the quantity and type of raw materials and packaging materials required to complete the tasks set out the reworks daily schedule (BOM).
- Source adequate and correct “raw” material and packaging material (BOM) in time to be used for the scheduled reworks tasks.
- Receive all picking slips for the inventory to be reworked and assign it to the Reach Truck Operator, to pick the inventory from the picking bin locations.
- Allocate the picking of BOMs (afternoon) and binning of the completed BOM’s (morning) accordingly
- Assign Rework Packers to the reworks task(s) for the day according to daily production schedule. Each task should have a team and production line to accomplish the task.
- Continuously supervise and check the teams to ensure that the inventory is not damaged and is clean before and after the task is completed.
- Check the BOMs to ensure that the teams signed as acceptance that no shortages were received.
- Apply the defined workflow correctly and ensure that it is adhered to.
- Conduct bi-weekly training sessions with the team to ensure that they stay up to date with the requirements in the Department.
- Communicate the daily production schedule to the team in the morning briefing sessions.
- Monitor the efficiency and effectiveness of Reworks workflow and make adjustments where needed.
- All completed reworks tasks must be consolidated on the generic pallets. All Consol pallets must be returned to Consol
- Supervise the team to ensure that all completed reworks tasks are completed daily as set out in the reworks schedule. Report any reason why the BOMs are not completed, on email to the Warehouse Manager.
- Carry out a physical check, against the sample which has been approved, at periodic times during the production of the BOM, ensuring items manufactured are exactly the same as the approved sample.
- Monitor hourly production volumes. Should the actual hourly production volume be less than the planned volume, assess the root cause and apply the corrective remedy measures.
- In the event that the reworked case/carton, barcodes, and quantities are short of the quantity set out in the reworks schedule, investigate why the SOP on receipt of BOM
- components from Reach Truck Operator, and the SOP on hand over to operator was not followed. Find the source of the problem and rectify as not to occur again.
- Note the inventory items and quantities that have been reworked and are to be binned.
- Follow the Put Away Policy and Procedure in binning the entire reworked inventory.
- Hand-over Product and BOM to the Inventory Team once BOM has been closed for Inventory Team to bin.
- The Reworks Section is required to carry out a cycle count of bin location containing reworked inventory items.
- The Cycle Count for the Reworks section will be carried out on a daily basis. All steps in the Cycle Count Policy and Procedure will be applied when executing the cycle count for the Reworks section.
- Check all products before leaving the Reworks Department to ensure that products and processes meet the established quality standards.
- Examine products and resolve any issues to:
- improve the quality,
- enhance customer satisfaction, and maintain the company's excellent reputation
- Be meticulous in their observations and checks
- Communicate clearly and actively throughout the business units with the relevant
- stakeholders (Planning and Management).
- Prepare correspondence, reports, statistics related to the Department operations area of responsibility, and operations, maintenance, and safety manuals.
- Define or redefine key performance indicators for every role in the Reworks Department to measure effectiveness of the Department’s operations.
- Interview, select, coach, train, manage, and appraise the performance of the Reworks
- Department’s staff.
- Problem solving, negotiate, and address staff challenges in the Department. Continuously evaluate the Department’s operations and highlight potential problems or opportunities identified in the operation.
- Cultivate a culture of teamwork in the Department.
- Manage and maintain staff performance levels to ensure KPI and SLAs are met continuously.
- Institute disciplinary proceedings with the HR Department on any Employee who fails to adhere to the KPIs, JDs and any other documented regulations or measures.
- Escalate any incidents pertaining to the Department that require the involvement and attention of the Warehouse Manager and/or senior management.
- Carry out any other duties as maybe required by the Warehouse Manager and/or company Senior Management time to time
- Check all staff’s clothing to ensure that they are dressed in the appropriate PPE issued to them.
- Collect data and ensure the performance of individual staff and/or teams in the Dispatch Department according to set KPIs.
- Complying with Company procedures, rules, and regulations.
- Wear PPE at all times.
- Train and upskills staff to ensure they all adhere to the OHS requirements
