Production General Foreman - Paper Machine

Primary Function:

The incumbent provides effective direction and supervision of Paper Machine Areas of Otsego Paper LLC to meet the TPH expectations from the mill. The areas of responsibility include but are not limited to Wet End staff and operations, Dry End staff and operations, RPM support, area environmental compliance, supporting plant capital planning, supporting risk mitigation (including fire protection), purchasing/procurement, area infrastructure and utilities.

Basic Requirements:

• Must be able to perform this job safely.
• Experience with operator/supervisor development and training.
• Experience with development and implementation of operator training materials.
• Must be able to effectively utilize DCS and Ignition systems to evaluate process systems for optimization opportunities.
• Ability to develop successful relationships with manufacturing, engineering, tech services, research, sales and customers to determine product specifications and maximize product reliability and acceptance. Highly developed technical skills with an ability to propel the plant forward by recognizing and implementing advancements in automation and technology.
• Must be able to enter, update and investigate safety incidents in CORE in a timely manner.
• Maintain safe working conditions for all departmental reports and ensure their compliance with Plant Safety Programs.
• Coordinate all safety model programs of responsibility (i.e. training) on a plant-wide basis.
• Assist with the administration of the RPM Model and reliability activities. Share responsibility with the PMC, Maintenance Supervisor and Planners to define work order schedules. Also, shares responsibility to develop and implement corrective action identified through reliability investigations in a timely manner to insure physical, electrical and mechanical asset health to the maximum extent possible.
• Develop and conduct a program for continuous in-plant skills training and development for areas under management and adjacent technical areas of responsibility. Annually review and update the materials to reflect process changes.
• Maintain well organized and accurate records relating to equipment maintenance, process efficiency, government agency reports, permits and material requisitions.
• Develops and coordinates and comprehensive departmental responsibility program contributing to the total plant objective of maximum profit through low delay, improved productivity, and maintenance cost control.
• Ensure compliance with local, state, Factory Mutual and Company environmental and safety regulations. Recommend and implement corrective actions which can be made to meet this goal.
• Can read and follow basic P&ID's, electrical one-lines, mass and energy balances, etc..
• Has experience with SCADA and DCS operations to support areas during process upsets or coverage requirements.
• Responsible for maintaining a high level of morale within the department to aid productivity and employee retention.
• Display competencies in the following areas: communication, decision making/problem solving, developing others, energy, drive, ambition, job knowledge, leadership, managing conflict/negotiation, managing resources, work quality and effective leadership.
• Familiarity with manufacturing initiatives such as Lean Manufacturing, Lean Six Sigma, 5S, Visual Work Management and Operator Basic Care and possesses the skills to ensure that implementation and utilization of the initiatives is effective in the paper mill.

Job Procedures and Requirements:

Reporting to the Production Manager, the incumbent is foremost responsible for the safety of the areas of supervision and must continually elicit a high standard of safety performance from the personnel under their supervision. The General Foreman must not only be proficient in all aspects of Paper Machine operations but equally competent in their general managerial abilities since they are required to provide direction, guidance, and motivation to their employees. The individual will make recommendations on such matters as discipline, performance assessments, terminations, layoffs, promotions, and transfers.

This position consists of but is not limited to the following job roles and responsibilities:

• Management of the Paper Machine equipment and process controls:
• Optimization of operations
• Ensure proper maintenance of all equipment
• RPM Program requirements
• All inspections and SAR requirements
• Management of contemporary Paper Machine equipment and process control:
• Distributed Controls Systems (DCS)
• Headboxes
• Vacuum Systems
• Press Dewatering Equipment
• Dryer Equipment
• Reel Equipment
• Winder Equipment
• Finished Roll Handling Equipment
• Experience with papermill equipment reliability:
• Inspections
• Pumps
• Motors
• Gearboxes
• Valves
• Flowmeters
• Switches
• All other requests by Production Manager (support).

The incumbent must ensure that their areas of supervision are sufficiently staffed with properly trained personnel to meet operational requirements. This requires the incumbent to be personally involved in the training of technicians to insure an adequate back-up for all key positions.

The incumbent also functions as one of the plant's Model Program Administrators and is responsible for (1) conducting periodic inspections in accordance with state regulations, insurance carriers' requirements, and Company Safety programs; and (2) conducting training of plant personnel in accordance with the plant's Model Program requirements.

The incumbent must keep abreast of technological improvement opportunities to recommend changes to enhance the mill operations. He/she must also be fully proficient in supervising employees in troubleshooting equipment malfunctions, preventive maintenance work, and routine equipment repairs and overhauls. He/she is also responsible for the coordination of various vendor services and capital projects under the direction of the Production Manager.

Qualifications:

• Bachelor's Degree in Engineering preferred.
• 5+ years of prior papermill operations experience preferred.
• 5+ years of prior Supervisory or Management experience preferred.
• SCADA (DCS, Ignition, etc..) experience.
• Higher level computer skills using Foxboro, ABB, Ignition, Rockwell, etc..
• USG Safety Model Program, OSHA, FM Global and Environmental compliance experience preferred.

Rate of pay may be adjusted based on the qualifications and experience of the candidate.

USG employees enjoy a number of benefit options for themselves and their families. These include two medical insurance options, as well as vision and dental coverage. The cost of these optional programs varies based on coverage level - employees generally pay 25% of the monthly premium cost, USG pays the rest. These coverage options are offered on the first day of employment with no waiting period.

Additionally, USG employees enjoy both a 401(k) Investment Plan with company match and a pension plan. Beyond these main features, employees may also choose from a number of additional programs like life insurance, accident insurance, legal insurance, even pet insurance, just to name a few. USG also offers Quarterly (hourly) / Annual (salary) bonus potential for all employees based on performance metrics tied to safety, quality, and productivity. USG also provides employees with paid time off and paid holidays.

Since 1902, Chicago-based USG has been a leader in producing innovative, award-winning products and systems to build everything from major commercial developments and residential housing to home improvements. USG's employees are committed to the highest levels of customer satisfaction and quality in everything we do. Our steadfast commitment to the company's core business values - innovation, quality, integrity, service, diversity, efficiency and safety - have helped us become the company we are today.

EOE including disability/veteran