Senior Industrial/Business Optimisation Engineer (Hay level 16/D1) Internal/External

Job Purpose • To optimise complex manufacturing processes, systems, and operations by applying industrial engineering principles, lean manufacturing methodologies, and Total Productive Maintenance (TPM). • The role is responsible for improving efficiency, productivity, and quality while reducing operational costs and waste. • The incumbent will design production layouts, analyse workflows, implement best manufacturing practices, and develop robust planning and capacity systems. • Additionally, the role will lead project coordination activities and guide planning and operations teams to achieve operational excellence Key Performance Areas Job Requirements 1. Industrial Engineering & Process Optimisation • Analyse, redesign, and improve manufacturing processes, workflows, and systems • Conduct time studies, method studies, and work measurement analysis • Perform line balancing and throughput optimisation • Develop and maintain standard operating procedures (SOPs) • Identify bottlenecks and implement process improvement solutions 2. Data Analysis, Simulation & Modelling • Utilise simulation software to model and optimise production systems • Apply statistical methods and mathematical models to analyse operational data • Simulate process changes and predict operational outcomes before implementation • Develop data-driven insights to support decision-making and continuous improvement • Build analytical models for capacity planning, workflow optimisation, and efficiency improvement • Use advanced Excel, Power BI, or similar tools for performance reporting and dashboards 3. Lean Manufacturing, Continuous Improvement and Total Productive Maintenance (TPM). • Lead the development and execution of an integrated Operational Excellence framework combining Lean Manufacturing, Continuous Improvement (CI), and Total Productive Maintenance (TPM) principles. • Drive end-to-end waste elimination across all manufacturing processes by applying Lean tools such as 5S, Kaizen, Value Stream Mapping (VSM), SMED, Kanban, and standardised work. • Identify, analyse, and eliminate inefficiencies in processes, equipment, workflows, and resource utilisation to improve productivity, quality, and flow. • Facilitate structured continuous improvement initiatives, problem-solving workshops, and cross-functional improvement projects. • Establish and sustain a culture of continuous improvement across production, planning, engineering, and support functions. • Lead TPM implementation to improve equipment reliability, uptime, and Overall Equipment Effectiveness (OEE). • Drive the implementation of preventive, predictive, and autonomous maintenance systems in collaboration with maintenance and production teams. • Reduce breakdowns, defects, minor stops, and chronic equipment losses through data-driven reliability improvement initiatives. • Integrate Lean, CI, and TPM activities into a unified improvement roadmap aligned with business objectives and cost reduction targets. • Define and track key performance indicators (KPIs) such as OEE, downtime, cycle time, scrap rates, and process efficiency improvements. • Ensure sustainability of improvements through standardisation, visual management, and ongoing performance monitoring. 4. Facility Layout & Industrial Design • Design efficient workstation layouts and production flow systems • Optimise material handling systems and internal logistics flow • Develop warehouse layouts and storage optimisation systems • Improve space utilisation and ergonomic workstation design • Ensure layouts support lean flow and reduced handling waste 5. Planning, Capacity & Production System • Develop and implement production planning and capacity modelling systems • Analyse demand vs capacity and recommend optimisation strategies • Improve scheduling accuracy and production sequencing • Support S&OP (Sales and Operations Planning) processes • Ensure alignment between planning systems and operational capability 6. Cost Engineering, Estimation & Analysis • Develop cost estimation tools, models, and systems for manufacturing processes • Support cost engineers and cost estimators with engineering inputs • Estimate production costs for processes, products, and projects • Evaluate operational efficiency and cost drivers • Analyse variances between estimated and actual production costs. 7. Cost Reporting & Management Support • Prepare detailed cost analysis and operational performance reports • Present findings and recommendations to senior management • Support strategic decision-making with data-driven insights • Track cost-saving initiatives and report ROI of improvement projects • Develop dashboards for cost, efficiency, and productivity monitoring 8. Project Co-ordination & Execution • Support the coordination and execution of cross-functional engineering and optimisation projects from initiation to completion, ensuring alignment with operational and business objectives. • Develop and implement a Performance Measurement System (PMS) to track project effectiveness, operational efficiency, and improvement outcomes. • Define and monitor key performance indicators (KPIs) to measure project progress, performance trends, and overall impact. • Provide ongoing performance monitoring, analysis, and reporting to support data-driven decision-making by management and stakeholders. • Identify risks, deviations, and improvement opportunities, and support corrective actions to ensure successful project delivery. • Drive training and coaching initiatives to build capability in performance measurement, project execution, and continuous improvement practices across teams. 9. Leadership & Team Development • Lead and mentor operations and planning teams • Provide technical guidance on optimisation methodologies • Develop team capability in Lean, data analysis, and process improvement • Promote accountability and performance-driven culture 10. Cost Reduction & Operational Excellence • Identify and implement cost-saving opportunities across operations • Reduce waste, scrap, rework, and inefficiencies • Improve labour, machine, and material utilisation • Benchmark and implement best manufacturing practices 11. Safety & Compliance • Ensure compliance with engineering and manufacturing standards • Support internal audits and continuous improvement audits • Comply with Necsa’s Health and Safety requirements • BBS observations and Safety incidents. • Promote a Nuclear Safety Culture within NECSA group • Contribute to improvement or streamlined world class Safety Systems • Implement best-in-class industrial engineering practices