Manufacturing Excellence Coach

About the role

• The Global Manufacturing Excellence (Manex) Coach is responsible for driving continuous improvement initiatives, optimizing manufacturing processes, and fostering a culture of excellence within the manufacturing environment. This role involves identifying areas for improvement, implementing best practices and BCOS work processes, and coaching teams in our manufacturing footprint to achieve best in class performance across the factories balanced score card.
• The primary focus of Manuf. Exc. Coach is to impact business performance by consistently enhancing competences of BC leaders, Support functions and Core team colleagues in line with BC Values and BCOS principles. A critical deliverable for this role is the creation of a manufacturing working environment of high-performing with a ZERO LOSS mindset and a culture of 100% participation. The impact of the role is measured through the tracking progress of Plants Manufacturing KPI’s Balanced Score card and progress of plant maturity level with implementation master plans.
• The primary responsibility of Manufacturing Excellence Coach is to assure the proper level of skills and qualification resides at the plant or facility to successfully deploy the loss elimination skill needed to deliver the site CBN. Provide Site Leadership a calibrated assessment of BCOS implementation from a point of view of total integration of the pillars. Provide direct coaching to Site Leadership teams so they know what the next step is, why the next step is important and how to do the next step. Promote reapplication of approaches and techniques globally while assuring the tools used are being used according to the standard. Ensure close alignment with the BCOS strategy for the Region, effective application of all work processes to the elimination of losses and integration across pillars. 

Key responsibilities include

• Shapes and drives the implementation of the BCOS (Barry Callebaut Operating System) program and strategic projects in alignment with the Global CSD (Customer Supply & Development) “Go For Zero” ambition
• Map the maturity of the sites against the BCOS framework, build the Manuf. excellence road map together with the Cluster Leads, Plant Managers and BCOS Director.
• Provide education/capabilities to site pillar leaders and support on their certification process. Assess and educate site leaders on pillar work process and maintenance of site pillar boards.
• Coach the sites CI leaders and Plant Leadership Team to drive change management aspects of all BCOS (process and culture) to impact directly plant results
• Conduct regular assessments on pillar work processes, routine management adherence (RTT) identifies opportunities for improvement and develop actionable insights and provide correct actions recommendations plus follow ups
• Drive program priorities and focus of pillar work process based on data analytics and performance metrics – addressing site business objectives (CBN and financials)
• Encourage benchmark continuously, referring plant to learn and share best practices to/from other plants
• Execute improvement initiatives at a tactical level i.e. working closely with site to implement best practices, standardize work processes, and improve operational efficiency
• Engage with frontline employees, cell leads/supervisors, and middle management through hands-on coaching (GEMBA), mentorship, and guidance. Direct involvement in day-to-day operations, processes, to understand capabilities gaps and program corrective actions
• When required facilitate workshops and training sessions to develop pillar work processes competencies
• Provide education to local sites/pillar leads on BCOS work process in line with program maturity (Phase 0 to Phase 4) and expected assessment criteria results
• Collaborate with cross-functional teams and stakeholders. Leverage global standards and Technical Platforms communities encouraging the ”give and get” and horizontal replication of company current best approaches (CBA)
• Maintain strong connection with the Global CI communities, educate and encourage digital adoption towards achieving best in class performance and smart factory status
• Act as a catalyst for change, inspire, motivate, and empower teams to embrace change, adopt best practices, and drive operational excellence
• Transform a full set of factories into a new era of technological advances with great attention to the human aspect and change management, developing and seeing shop floor operators taking ownership and pride in their work and performance
• Own the BCOS program at Regional level Assures BCOS activities have a connection to loss elimination that will deliver required CBN results.
• Coach on BCOS technologies and approaches in all pillars to include on-the-floor activities.
• Assessor of integrated activity implementation and standards calibrator with leadership team.
• Participates in all phase assessments to provide a calibrated and objective viewpoint
• Capture and disseminate Current Best Practices worthy of reapplication
• Establish contract with plant manager and site BCOS manager.
• Diagnose activities and identify technical know-how and organization behaviors that are barriers to implementation.
• Provide feedback to leadership teams that cause them to take action.
• Address current capability needs to deliver the BU CBN Develop capability in leadership teams and especially in the BCOS manager whom they qualify.
• Share and receive learning with and from other BCOS managers to foster global skill development. Each consultant should seek out a mentor/peer coach relationship that will provide support, calibration and skill development. This should be mandatory for all coaches.
• Tour sites at least once in two months (Or Need basis) with Leadership Pillar Team to understand BCOS progress, execution status, help needed and reapplication opportunities.
• Support Global Pillar owner assessments.
• Have 1:1 meeting with Global pillar leaders to adjust pillar master plans on need basis
• Address future capability needs to deliver the Regional CBN Look ahead for what capabilities will be needed in the next 6 to 18 months.
• Network with other Regional’s and external organizations to keep abreast of what's going outside our own business
• Involve in critical systems development.
• Working with Regional lead sites as appropriate
• Coordinate and participate in lead models to define the standards for site implementation
• Get training from Global /corporate teams
• Lead BU/regional BCOS Networks Lead Regional networks
• Consolidate Regional level BCOS progress.
• Works closely with regional leaders to ensure the site is receiving effective guidance/coaching and leads on best-in-class systems/tools for reapplication
• Provide regular updates COE team on Regional progress

About you 

• Bachelor's degree in Engineering, Operations Management, or related field. TPM / IWS , Six Sigma or Lean certification preferred.
• Strong understanding and know-how of Lean manufacturing principles, Six Sigma methodologies, Total Productive Maintenance (TPM) and other improvement techniques
• Analytical mindset with the ability to visualize and interpret data or metrics
• Project management skills to oversee multiple improvement projects simultaneously
• English language proficiency is required
• Coaching/Consultancy Skills: This role requires the ability to deliver results through others.

• • Demonstrated ability to develop capability in Managers, Technicians and Contractors.
  • Able to identify and leverage the unique capabilities of others and build successful teams.
  • Demonstrated ability to inspire others and lead cultural change in a mature organization.

• Travel requirements: between 50 to 75% within region or sporadically traveling globally
• Shop-floor orientated role, hence regular on site presence is crucial
• Metrics of Success across the balance score card:

• • SHE: ZERO safety incidents, continuous improvement of metrics on environment impact
  • Quality: Zero Food Safety Incidents and Quality Defects
  • Delivery: OEE +85% and Sch. Adherence +90%
  • Cost: continuous improvement manhour/ton, FTC consistency reduction, Productivity +4% YOY
  • People: +90% score engagement survey (100% participation), Talent pipeline at least 1 talent critical jobs

• At least 10 years of experience in manufacturing environment with in-depth knowledge of production, quality, process control, asset management, cost structures and digitalization, in a multinational business context
• Ability to identify and eliminate defects and losses across the Supply Chain.
• Has a minimum operation experience and has the skills of at least the phase of where the plant or facility is currently working.
• Has had a line assignment in manufacturing and developed On-the-floor credibility with people doing the work.
• Technical skills in each pillar.
• Fundamental skills in all pillars, in-depth skills in at least two pillars, minimum of level 3 qualification in Problem Solving, Standardized Work, VSM, Leadership Envisioning, and DDS including RTS.
• Technical skill level requirements should be a little ahead of sites being consulted. The BCOS learning card should be completed to the appropriate skill level within 6 months of obtaining the role.
• Able to influence plant managers and plant leadership teams, and Directors as required.
• Demonstrated ability to lead and cause positive cultural change within teams or organizations.
• Able to influence and motivate people with diverse skills and experiences to achieve excellent results.
• Self-motivated to resolve issues and follow-through to completion (especially complex technical or capability issues).
• Has passion for the work and can help others see the vision.
• Able to collaborate confidently and effectively across several organizational boundaries (language, geographic, business unit).
• Ability to lead and participate on global and multi-functional teams.
• Ability to coach and inspire other Managers and technicians to deliver operational excellence.
• Personally, committed to self-development required of the role. Is an active listener but can confront and be assertive.
• You get energized from developing people and seeing operational results
• You thrive in an international and multicultural environment
• You are highly motivated to bring change to an organization
• You like being on the Gemba , working with site teams and interacting with CI communities in order to bring change
• You embrace D&I (Diversity and Inclusion) and willing to go the extra mile in order to deliver on the organizational targets