Production General Foreman - Paper Machine

About the Role

The incumbent provides effective direction and supervision of Paper Machine Areas to meet throughput expectations. Responsibilities include Wet End and Dry End staff and operations, RPM support, environmental compliance, capital planning, risk mitigation (including fire protection), purchasing/procurement, and area infrastructure and utilities.

Responsibilities

• Utilize DCS and Ignition systems to evaluate and optimize process systems.
• Develop relationships with manufacturing, engineering, tech services, research, sales, and customers to determine product specifications and maximize reliability.
• Implement advancements in automation and technology to propel plant operations forward.
• Enter, update, and investigate safety incidents in CORE in a timely manner.
• Maintain safe working conditions and ensure compliance with Plant Safety Programs.
• Coordinate safety model programs (e.g., training) on a plant-wide basis.
• Administer the RPM Model and reliability activities, including defining work order schedules and implementing corrective actions.
• Develop and conduct continuous in-plant skills training and development programs, updating materials annually to reflect process changes.
• Maintain organized records for equipment maintenance, process efficiency, government agency reports, permits, and material requisitions.
• Develop and coordinate departmental programs to maximize 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.
• Support process upsets or coverage requirements using SCADA and DCS operations.
• Maintain high morale within the department to aid productivity and employee retention.
• Demonstrate competencies in communication, decision-making, problem-solving, developing others, leadership, conflict management, and resource management.
• Implement and ensure effective use of manufacturing initiatives such as Lean Manufacturing, Lean Six Sigma, 5S, Visual Work Management, and Operator Basic Care.
• Manage Paper Machine equipment and process controls, including optimization, maintenance, inspections, and SAR requirements.
• Oversee contemporary Paper Machine equipment (e.g., DCS, headboxes, vacuum systems, press dewatering, dryer, reel, winder, and finished roll handling equipment).
• Ensure equipment reliability through inspections and maintenance of pumps, motors, gearboxes, valves, flowmeters, switches, and other components.
• Ensure areas of supervision are staffed with properly trained personnel, including personal involvement in training technicians.
• Serve as a Model Program Administrator, conducting inspections and training in accordance with state regulations, insurance requirements, and company safety programs.
• Recommend technological improvements to enhance mill operations.
• Supervise employees in troubleshooting, preventive maintenance, routine repairs, and overhauls.
• Coordinate vendor services and capital projects under the direction of the Production Manager.
• Make recommendations on discipline, performance assessments, terminations, layoffs, promotions, and transfers.

Requirements

• Ability to perform the job safely.
• Experience with operator/supervisor development and training, including development and implementation of training materials.
• Proficiency in reading and following P&IDs, electrical one-lines, mass and energy balances.
• Experience with SCADA and DCS operations (e.g., Foxboro, ABB, Ignition, Rockwell).
• Familiarity with USG Safety Model Program, OSHA, FM Global, and environmental compliance.

Qualifications

• Bachelor’s Degree in Engineering preferred.
• 5+ years of prior papermill operations experience preferred.
• 5+ years of prior supervisory or management experience preferred.

Benefits

• Two medical insurance options, vision, and dental coverage (employees pay ~25% of monthly premium).
• 401(k) Investment Plan with company match.
• Pension plan.
• Additional optional programs: life insurance, accident insurance, legal insurance, pet insurance.
• Quarterly (hourly) / Annual (salary) bonus potential based on performance metrics (safety, quality, productivity).
• Paid time off and paid holidays.