Production EngineerSan Miguel Corporation

Primary Functions
Conveying
Establishes optimum utilization of dosing bins and liquid tanks for mixing operations.
Determines the volume of needed raw and packaging materials based on production schedule. Plans for RM Bins filling including sequence, type of material, quantity and intake pit. Coordinates with Warehouse Management service provider on RM & PM withdrawal and issuance including liquids.
Verifies proper clean-out of all conveying lines in the intake section.
Guarantees the correctness of RM and its corresponding bin assignment including the correct day tanks for liquid ingredients. Implements controls to prevent cross-contamination.
Verifies the implementation of molasses dilution (if needed) and addition of anti-oxidant for oil deliveries.
Conducts periodic inspection of major equipment in the intake section including pumps and motors. Reports to Production Head any anomaly noted on equipment. Assists in removing accumulated foreign materials in cleaning equipment.
Establishes and implements energy conservation programs such as turning off all equipment in the intake section when not in use.
Determines sources of discrepancy between actual RM quantity transferred to production and the quantity in the Material Issuance Slip.
Records all RM and packaging material transfers from warehouse and storage tanks to production in SAP. Ensures accuracy of SAP entries including correct batch management data per material, implements proper record keeping, distribution and disposal of records.
Establishes consistent implementation of FIFO & FEFO.
Assists in the replacement of consumables and/or repair of equipment during breakdowns.
Assists in the monthly physical inventory count of materials.
Dosing
Designates the dosing bin assignment of RM needed for batching.
Guarantees that most up-to-date formula is used and that correct profile of RM is considered..
Ascertains the suitability of setup in post-grinding system by installing correct hammer mill screens and sifter screens in the mixing section and if necessary, make adjustment in the roll gap of Roller mill in coordination with FME-conveying to achieve the conforming particle size.
Verifies accurate addition of liquids in the mixer and homogenizer as required by the formulation.
Validates conformance to process parameters such as accuracy of batch weigher, accuracy of liquid injection system both in batch mixer and homogenizer, and mixer paddle to wall clearance.
Monitors and analyzes production yield and reports results of yield analysis.
Establishes correct setup of conveying lines to ensure correct products are sent to the correct pre-pelleting bin as well as the correct finished product bins to prevent cross-mixing.
Conducts cycle time analysis to determine bottle-necks and speed up the batching process, institute corrective and improvement actions to increase the output.
Monitors and analyzes sources of variation between actual and theoretical liquids usages in both mixer and homogenizer.
Verifies the adequacy of clean-out procedures and take actions to flushing remaining materials. Ensures proper segregation, identification and use of flush materials.
Validates the correctness of ingredients being poured in the hand-tipped section.
Conducts periodic inspection of major equipment in the mixing section including motors. Reports to Production Head any anomaly noted on equipment. Assists in removing accumulated foreign materials in cleaning equipment.
Establishes and implements energy conservation programs such as turning off all equipment in the Mixing Section when not in use.
Guarantees accuracy of RM usages in SAP and ensures accuracy of entries including batch management data, implements proper records management. Determines sources of discrepancy on RM usages.
Verifies batching accuracy and precision by implementing correct dosing set-up. Checks for incidence of over/under dosed materials and makes adjustments when necessary.
Coordinates with the FME-Conveying for any changes in production schedule or formulation to ensure timely replenishment of RM in dosing bins.
Coordinates with the FME-Pelleting regarding feed types to be sent to pelleting section for proper pre-pelleting bin assignment. Informs bagging personnel on finished product bin assignment.
Assists Maintenance personnel in the replacement of consumables and/or repair of equipment during breakdown.
Pelleting
Ascertains that process operating parameters are set to provide the desired quality of products.
Guarantees that all measuring and testing instruments are calibrated periodically.
Verifies the accuracy of liquid injection system including that of post pelleting liquid system. Analyzes source of variation between theoretical and actual usages.
Monitors the useful life of consumables (eg. Die, rolls, cutting knives, etc.) and provides feedback on reordering system.
Initiates the replacement of dies and rolls.
Verifies actual weight of finished product in bagging line is within the set target.
Determines the appropriate sifter screen size to achieve product size requirement.
Establishes and implements energy conservation programs such as turning off all equipment in the pelleting section when not in use.
Conducts periodic inspection of major equipment in the pelleting section including motors. Initiates periodic removal of accumulated dirt and foreign materials in cleaning equipment.
Conducts start-up and clean-out of equipment for every change in feed type. Ensures proper emptying of pre-pelleting bins, holding bins, product bins, hoppers and all equipment in the pelleting section to avoid cross-contamination.
Ensures that lubrication program is being implemented properly.
Maintains cleanliness and orderliness in the work area.
Assists maintenance personnel in the replacement of consumables and/or repair of equipment during breakdown.
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of equipment during breakdown.ineses and execute SmplementatioEnsures safety devices are functioning during start-up, operation and shut down.
Utilities
Ascertains sufficient and consistent supply of good quality steam, compressed air and power to production line.
Conducts steam boiler and air compressor start-up operations.
Inspects safety and protective devices prior to start-up and during operations.
Ensures that all valves of water supply are open, water softener and treatment system is functional, required boiler steam pressure is maintained, condensate return is recycled, feed water pump is functional, sufficient level of boiler water during operation, required feed water temperature is maintained, cut-in/cut-off is within operational standard and all valves are open going to process line from steam boiler.
Conducts daily cleaning of air filter, replenishes compressor oil level as needed, records running hours of compressor operation, records air pressure hourly and ensures proper air pressure cut-in/cut-off of compressed air system.
Implements energy conservation program and ensures all motors in the Utilities Section are turned-off when not in use.
Maintains safety inventory level of boiler fuel and initiates request for deliveries.
Ensures that annual preventive maintenance and mandatory compliant testing such as emission testing, pressure vessel of steam boiler, air compressor, dry and oil-filled transformers, substation and generator set are being conducted.
Maintains cleanliness in the work area.
Assists maintenance personnel during preventive maintenance activities.
Process
Verifies compliance to process operating parameters and achieve the desired quality of products through the implementation of physical testing such as particle size (D50), pellet durability, fines level, pellet length, texture and hardness.
Validates that all measuring and testing instruments are calibrated periodically.
Verifies the accuracy of weighing and dosing activities including that liquid injection system. Analyzes source of variation between theoretical and actual usages. Measures process capability of all feed milling equipment.
Verifies conformance of mixer equipment through mixing homogeneity test. Guarantees that all requirements for mixer paddle-to-wall clearance, leak-free mixing operation and mixer fill are satisfied.
Checks for incidence of over and under dosing of materials and recommends adjustments when necessary.
Optimize the moisture content of all products while adhering to water activity acceptable value. Analyzes the cause of low moisture content and recommends action plans for evaluation.
Nature of Interaction with Clients and Other Units
Unit
Position
Purpose
Operations
Production Head
Gives feedback on any information related to production (delays, no. of batches, output, trials)
QC
QC Analyst
Coordinates all nutritional and physical analysis of every feed type to as basis for continuous operation.
Operations
Inbound Planner
Gives feedback on the status of all critical RMs for the planner to follow-up the supplier.
Operations
Engineering Auditor
Coordinates feed mill equipment for inspection and repair to optimize production
Operation
PCSO
Coordinates all safety devices/pollution control devices for inspection and repair