Production General Foreman - Paper Machine

USG Corporation • Otsego Township, MI

91d • $82,560 - $110,040

About The Position

The Production General Foreman directs and supervises the Paper Machine areas of Otsego Paper LLC to meet mill production expectations. Areas of responsibility include Wet End and Dry End staff and operations, RPM support, environmental compliance, capital planning support, risk mitigation and fire protection, procurement, infrastructure, and utilities. Reporting to the Production Manager, the incumbent is foremost responsible for safety in the supervised areas and must promote high safety performance. The role also requires strong paper-machine operating knowledge and managerial skills to guide, develop, and motivate employees, and to make recommendations concerning discipline, performance assessments, terminations, layoffs, promotions, and transfers.

The position oversees paper-machine equipment and process controls, operations optimization, equipment maintenance, RPM program requirements, inspections, and SAR requirements. Relevant equipment and systems include DCS, headboxes, vacuum systems, press dewatering, dryers, reels, winders, and finished-roll handling equipment. The foreman supports equipment reliability through inspections and work involving pumps, motors, gearboxes, valves, flowmeters, switches, and other equipment. They must ensure adequate staffing and training, personally support technician training and backup coverage for key positions, and administer plant safety model programs, including periodic inspections and personnel training.

The incumbent maintains accurate records relating to maintenance, process efficiency, regulatory reports, permits, and requisitions; supports troubleshooting, preventive maintenance, repairs, and overhauls; and coordinates vendor services and capital projects under the Production Manager. The role also involves process optimization using DCS and Ignition, keeping current with technological improvements, maintaining environmental and safety compliance, and applying manufacturing improvement initiatives.

Requirements

• Must be able to perform the job safely.
• Experience with operator and supervisor development and training.
• Experience developing and implementing operator training materials.
• Ability to use DCS and Ignition systems to evaluate process systems and identify optimization opportunities.
• Ability to build effective relationships with manufacturing, engineering, technical services, research, sales, and customers to determine product specifications and maximize product reliability and acceptance.
• Strong technical skills and ability to recognize and implement automation and technology advancements.
• Ability to read and follow basic P&IDs, electrical one-lines, and mass and energy balances.
• Experience with SCADA and DCS operations to support areas during process upsets or coverage requirements.
• Experience with higher-level computer systems such as Foxboro, ABB, Ignition, or Rockwell.
• Competency in communication, decision-making and problem-solving, developing others, leadership, conflict management and negotiation, resource management, work quality, and related areas.
• Bachelor’s degree in Engineering preferred.
• Five or more years of papermill operations experience preferred.
• Five or more years of supervisory or management experience preferred.

Nice To Haves

• Bachelor’s degree in Engineering.
• Five or more years of prior papermill operations experience.
• Five or more years of prior supervisory or management experience.
• Experience with the USG Safety Model Program, OSHA, FM Global, and environmental compliance.

Responsibilities

• Direct and supervise Paper Machine area operations and staff to meet mill production expectations.
• Maintain safe working conditions and ensure personnel comply with plant safety programs; coordinate assigned safety model programs and training.
• Enter, update, and investigate safety incidents in CORE in a timely manner.
• Manage paper-machine equipment and process controls, optimize operations, ensure proper equipment maintenance, and meet RPM, inspection, and SAR requirements.
• Support reliability activities, define work-order schedules with the PMC, Maintenance Supervisor, and Planners, and implement corrective actions from reliability investigations.
• Develop and conduct ongoing in-plant skills training, update training materials annually, and ensure adequate staffing and backup coverage for key positions.
• Maintain organized and accurate records concerning equipment maintenance, process efficiency, regulatory reports, permits, and material requisitions.
• Ensure compliance with local, state, Factory Mutual, company environmental, and safety regulations, and recommend and implement corrective actions.
• Maintain departmental morale and support employee productivity and retention.
• Supervise troubleshooting of equipment malfunctions, preventive maintenance, routine repairs, and overhauls.
• Coordinate vendor services and capital projects under the direction of the Production Manager.
• Keep abreast of technological improvements and recommend changes to enhance mill operations.
• Apply manufacturing initiatives such as Lean Manufacturing, Lean Six Sigma, 5S, Visual Work Management, and Operator Basic Care.
• Make recommendations regarding employee discipline, performance assessments, terminations, layoffs, promotions, and transfers.

Benefits

• Two medical insurance options, with coverage available on the first day of employment and no waiting period.
• Vision and dental coverage.
• 401(k) Investment Plan with company match.
• Pension plan.
• Life insurance, accident insurance, legal insurance, and pet insurance options.
• Quarterly bonus potential for hourly employees or annual bonus potential for salaried employees, based on safety, quality, and productivity metrics.
• Paid time off.
• Paid holidays.

What This Job Offers

• Job Type: Full-time
• Career Level: Manager