Production Manager, Business Improvement Specialist, Process Engineer, Continuous Improvement Manager, Industrial Engineer (Manufacturing)

• Systematically apply common sense to deploy simple concepts, streamline processes and develop people.
• Implement Operational Excellence (OpEx) across RBM mining operations value chain.
• Partner with the Finance and operations teams to calculate cost reductions and document savings.
• Engage, train and coach mines operations teams to use basic lean tools to eliminate waste.
• Support business case development for new equipment or equipment upgrades.
• Conduct maturity assessments to make sure all mines adhere to Rio Tinto Safe Production System.
• Facilitate Kaizen events (problem-solving).
• Lead improvement initiatives/projects where required.

• Oversee Decoiling, Coating, Printing, Presses and 3 assembly lines (Large Drums, Small Drums and Jerry Cans).

• Plan production programs in liaison with planners considering - specs, priorities, raw materials and line resources.
• Negotiate and agree on production timeframes with Sales Account Managers.
• Ensure products are manufactured to Greif Quality Procedure Manual standards and shop packet requirements.
• Assessed labor utilization, monitored workstations (quality/target) and expedite factory workflow.
• Plan and schedule Autonomous Maintenance activities as part of Greif Business System in the factory.
• Coordinate repairs and implementation of planned maintenance programs for factory equipment.
• Manage WIP locations, raise cycle counts and investigate stock variances.
• Manage factory controllable costs and expenses (Scrap, Rework, Consumables, Overtime and Manning).
• Follow up and ensure actioning of internal/external audit findings (FSSC 2200/ISO/GMP/5S/GBS).
• Collaborate with HR to address IR issues e.g. leave, absenteeism, contracts, disciplinary and training.
• Ensure staff is aware and adhere to statutory requirements, policies and procedures (SHEQ).
• Organise and execute relevant product/process training sessions for factory staff.
• Lead continuous improvement initiatives from inception till successful completion.

• Oversee stores, production, repair centers, procurement and outgoing shipments.
• Manage 1 Supervisor, 13 Operators, 3 Technicians, 1 Store controller, 1 Buyer and 1 logistic coordinator.
• Hold weekly operations meeting to agree on repairs and sales orders delivery timeframes.
• Follow-up on delays, material shortage, kits and quality issues in-house/ externally.
• Support Safety/Qualityobjectives and ensure policies are readily available and practiced.
• Collaborate with HR to address IR issues e.g. performance, leaves, grievances, disciplinary and training.
• Manage department budget (OPEX) and control spending in relation to changing production volumes.
• Manage maintenance and calibration of production equipment/ tools/ jigs.
• Oversee procurement of raw materials, consumables, tools and outsourced processes.
• Ensure optimal stock levels of raw material, work-in-progress and finished goods.
• Oversee stock locations on SAP, raise cycle counts and investigate stock variances.
• Prepare external repairs quotes, follow-up on repairs and invoiced repair payments.
• Plan and coordinate safe demolition of irreparable equipment from sites.
• Oversee entire operations

Initiate and coordinate initiatives to improve safety, quality, cost, lead-time and production methods

• Evaluated BOMs, material flows, production schedules and engineering specifications.
• Conducted time studies to set performance standards, balanced lines and determined labour.
• Assessed labor utilization, monitored workstations (Safety/quality/target) and factory work flow.
• Continuous improvement 
• Attended daily production meetings, highlighted problems and provided regular feedback.
• Investigated equipment downtime, liaised with maintenance for repairs and improving uptime.
• Prepared cost expenditure proposals (CAPEX) to improve production processes where required.
• Planned and executed reduction of non-value-adding activities within production/warehouse.
• Collaborated with industrialization team to identify equipment and tooling required for specific tasks.
• Collaborated with configuration team to organize manufacturing documentation required for production.
• Collaborated with quality team to address process and product non-conformances.
• Evaluated, analyzed and re-designed production layout where required.
• Prepared reports for Senior Production Manager.

• Lead weekly operations meeting to estimate, negotiate and agree on timescales with project managers.
• Plan work schedule, maximize resource utilization and daily expedite planned work.
• Investigate equipment stoppages, work with maintenance to plan repairs and routine equipment maintenance and continuous improvements
• Manage stock of raw materials used in production and ensure all raw materials are accounted for.
• Ensure statutory requirements, policies and procedures are implemented and complied with by all staff.
• Liaise with quality and engineering to develop manufacturing documentation relevant for production.
• Ensure incidents are reported, investigated properly and closed within reasonable time frames.
• Work with HR to address IR issues timeously and effectively e.g. contracts, grievances and disciplinary enquiries.
• Manage and control department budget in terms of overtime, man hour per unit and headcount.
• Work with supervisors to improve key performance measures(PQCDSM).
• Initiate various CI initiatives within production (6S, 5Why, PDCA, OPL, 5W1H, Gemba, Kaizen, SOP, PQCDSM).
• Lead Gemba Walks, Root-Cause-Analysis and Kaizen activities.

• Conducted audits, analysed audit findings and assisted stakeholders with action plans to close gaps.
• Provided practical support during implementations and updated progress tracking system for Best Practices.
• Compiled training material, facilitated training, coached section managers and team leaders.
• Documented, evaluated and analyzed production processes to identify non-value-adding activities.
• Planned and executed reduction of all forms of waste within production/warehouse operations.
• Standardized stores work methods, optimized space and material storage.
• Investigated BOMs, material flows, production schedules and engineering specifications.
• Conducted time studies to set performance standards, balanced lines and determined labour.
• Introduced structured team meetings and visual performance management areas (QCDSM).
• Participated in daily team meetings, highlighted problem areas and facilitated problem-solving.
• Investigated equipment downtime, liaised with maintenance for repairs and improving uptime.
• Implemented visual workplace concept - demarcations, labeling, safety mirrors and signage.
• Reported monthly savings resulting from improvements initiatives.

• Render solutions for business improvement through implementing 20 Keys™ Methodologies.
• Conduct audits, analyze findings, make recommendations and present reports.
• Formulate improvements action plans to close the gaps.
• Manage a progress tracking system for implemented methodologies.
• Identify, propose, plan and manage impact/profit improvement projects.
• Facilitate workshops on Methodologies indicated below:
• Methodologies implemented: 4S; Goal alignment and Mini-business; Small group activities; Single-minute-exchange of dies; Kaizen of operations; Maintaining machines and equipment; Workplace discipline; Quality assurance; Eliminating waste; Efficiency control; Skill versatility and cross training.
• Provide support during defects, equipment downtime, lead time and wastes reduction projects.

• Provided solutions to improve production processes through Lean - TIMWOODS, VSM, 5S, OEE, SMED, A3 Report.
• Evaluated production methods and proposed solutions to reduce overall production waste.
• Planned and executed reduction of non-value-adding activities within production.
• Conducted time studies to set performance standards, balanced lines and determined labour.
• Introduced daily morning meetings and visual performance management areas (QCDSM).
• Participated in daily team meetings, highlighted problem areas and facilitated problem-solving.
• Compiled, trained and implemented various lean manufacturing standards at shopfloor.
• Collaborated with production supervisors to address subordinate’s performance challenges.
• Collated production data, investigated abnormalities and provided feedback to management.
• Investigated equipment downtime, liaised with maintenance for repairs and improving uptime.
• Assisted to implement Quality Management system (ISO 9001: 2000).
• Developed packaging/assembling/ change-over instructions and ensured compliance.
• Implemented visual workplace concept - demarcations, labeling, safety mirrors and signage.
• Prepared reports to senior management for review and decision-making.

• Assisted to implement Quality Management System (ISO 9001: 2000).
• Developed production visual aids, on/off-loading truck’s procedure, packaging instructions and check sheets.
• Verified incoming shipments, conducted material inspections and raised non-conformances.
• Updated drawings on Syspro and communicated changes to production personnel and Logistics Manager.
• Updated and verified Bills of Material regularly for accuracy and relevancy.
• Conducted time studies to set performance standards, balanced lines and determined labour.
• Implemented production data sheets, analysed data, improved output/ downtime/ quality.
• Hired, trained, directed production staff and reviewed daily performance targets.
• Ensured production staff awareness and practice of company policies, procedures and standards.
• Implemented visual workplace concept - demarcations, labeling, safety mirrors and signage.
• Planned and executed production/ warehouse methods improvement initiatives.
• Obtained quotes, outsourced contractors for plant maintenance and equipment repairs.
• Monitored consumption of critical spares, welding consumables and ensured optimal stock levels.
• Prepared reports to senior management in relation to the above responsibilities when required.

• Established criteria to ensure supplier’s vehicles compliance to service level agreements.
• Coordinated supplier audits to collect data, analyzed findings and presented recommendations.
• Established warehouse standards - verifying orders, ABC storage strategy, loading/unloading delivery vehicles.
• Evaluated warehouse processes (AS-IS) and proposed process improvement solutions (To-Be).
• Planned and executed continuous improvement initiatives within warehouse operations.
• Initiated visual workplace concept - demarcations, labeling, safety mirrors and signage.
• Prepared documents for counting stock, captured stock counts on system and investigated variances.
• Coordinated and supervised material pickers during assembly parts picking.
• Designed material handling storage equipment - mobile bins/cages/stillage.
• Reviewed inventory levels to ensure optimal stock levels and minimize shortages.
• Assisted to follow-up incoming order shipments and determine estimate time of arrival.