Lead – Refinery Plant (Production, Performance & Operational Excellence)

Department: Operations / Manufacturing

Location: Thika
Industry: Refinery /Process Manufacturing

Salary: Ksh 250,000 Gross

Age: 35-45 years

Nationality: Kenyan Nationals only

Joining: Immediate

Key Responsibilities

1. Production & Operations Management

· Lead and supervise refinery production operations to achieve daily, weekly, and monthly output targets.

· Ensure consistent product quality and adherence to process standards.

· Implement best manufacturing practices (5S, Lean, TPM, Six Sigma).

· Monitor plant KPIs including throughput, yield, recovery, downtime, and cycle efficiency.

· Coordinate with planning, logistics, and procurement for uninterrupted raw material and supply flow.

2. Stock Variance & Material Accountability

· Oversee and reconcile daily, weekly, and monthly stock reports (RM, WIP, FG).

· Identify, analyze, and resolve stock variances through root cause analysis and control measures.

· Strengthen internal controls to maintain accurate material balances (input vs. output).

· Collaborate closely with inventory, warehouse, and finance teams to ensure accurate reporting.

3. Efficiency, Performance & Optimization

· Track and improve operational parameters including process yields, energy consumption, throughput time, and OEE.

· Lead continuous improvement projects to reduce losses, improve productivity, and enhance cost efficiency.

· Evaluate process bottlenecks and implement corrective action plans.

· Drive digitalization/automation initiatives (SCADA, DCS, IoT, process analytics).

4. Maintenance Coordination

· Work with the maintenance department to plan and execute preventive, predictive, and breakdown maintenance activities.

· Ensure equipment reliability and minimal unplanned downtime.

· Participate in shutdown planning, execution, and performance evaluation.

· Maintain compliance with mechanical, electrical, instrumentation, and safety standards.

5. Quality, Safety & Compliance

· Enforce strict adherence to quality control parameters and statutory guidelines.

· Ensure compliance with ISO standards, environmental norms, and safety regulations.

· Conduct risk assessments, safety audits, and process safety management (PSM) activities.

· Promote a strong culture of safety, discipline, and continuous improvement.

6. Leadership & Team Development

· Lead, coach, and mentor production supervisors, operators, and technical support teams.

· Build capabilities through training, performance assessments, and skill-enhancement programs.

· Foster a culture of accountability, teamwork, and process excellence.

Qualifications & Experience

· Bachelor’s degree in Chemical/Mechanical/Industrial Engineering (Master’s preferred).

· 8–15+ years of relevant experience in edible oil refinery.

· Strong knowledge of refinery processes, utilities, DCS/SCADA systems, and mass balance principles.

· Proven experience in production planning, process optimization, and efficiency improvement.

· Familiarity with Lean, Six Sigma, TPM, OEE, and continuous improvement methodologies.

· Hands-on knowledge of maintenance systems (CMMS, preventive maintenance, etc.).

Key Skills & Competencies

· Strong analytical and problem-solving abilities.

· Excellent leadership, communication, and team-management skills.

· Proficiency in data-driven decision-making and operational analysis.

· High attention to detail with strong ownership and accountability.

· Ability to work under pressure and manage multiple operational priorities.

Performance Indicators (KPIs)

· Production volume vs. target

· Stock variance (% accuracy)

· Overall Equipment Effectiveness (OEE)

· Yield and recovery improvements

· Energy efficiency and cost reduction

· Compliance with safety and quality standards

· Downtime vs. uptime ratio

· Team performance and skill enhancement