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

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

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

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.

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

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

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.

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

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.

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

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

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

Requirements Key Knowledge & Skills:

• Knowledge of materials, fabrication processes, quoting and legal implications
• Interpretation of technical drawings
• An ability to understand and assess technical problems, enabling you to
• generate solutions through application of process knowledge, experimental trials
• and process development.
• The ability to identify and develop leads during technical conversations and to
• generate ideas for internal/external/collaborative development projects.
• Excellent planning and organisation skills applicable to scoping, launch and delivery of projects to time, cost and quality targets.

Technical and Behavioral Competencies

• Problem Solving
• Analytical Thinking & Attention to Detail
• Time & Self-Management
• Drive Results Orientation
• Assertiveness
• Excellence / Quality Orientation
• Relationship Building
• Customer Service Orientation
• Communication
• Teamwork
• Safety Orientation

Minimum Qualifications

• Degree in Industrial Engineering OR Operations Management.
• General computer literate to at least intermediate level Windows, MS Project, MS Word and Excel

Minimum Experience

• 10 years in manufacturing/ industrial engineering environment
• Strong experience in Lean Manufacturing, TPM, CI implementation
• Minimum 5-7 years in fabrication environment advantageous
• Strong analytical and problem-solving skills.
• Advanced knowledge of production mac