PRODUCTION | CONTINUOUS IMPROVEMENT | ENGINEERING
Objective
Manufacturing Manager, bringing 13+ years’ lean manufacturing, engineering, project management, ERP, continuous improvement experience and leadership skills gained in the chemical, oil refinery, pharmaceutical packaging, precision machining, and printing industries.
Relevant Experience:
Engineering Management AECI 8.5 years
Manager, AECI Exactum 4.5 years
Managed a precision machining company for 4.5 years of 44 personnel, improving quality, lead times, on-time delivery and profitability.
* Involved staff and customers to create detailed annual business, operating and marketing plans. Used these plans to drive continuous improvement efforts and achieved 95% of all annual targets and goals set.
* Used lean manufacturing techniques to move from a loss situation to making 6% net profit per year.
* Set annual machine rates, labor rates and company budgets.
* Introduced cross-training to reduce waiting times and bottlenecks, resulting in 25% reduction in manpower costs while sustaining 10% annual growth rate.
* Created a centralized tool store and reduced annual tooling costs by 10%.
* Set up a company task force to implement ISO 9002. Awarded ISO 9002 quality assurance certification on the first audit with a high level of compliance and sustained this level for 2 years.
* Introduced Total Productive Maintenance principles, training company machinists, and bringing all critical production machinery back to standard operating condition or better.
* Upgraded and used MRP computer system to schedule production and identify production bottlenecks.
* Instituted safety and quality teams to audit company, make recommendations and perform remediation work.
* Skilled at communicating and motivating all levels of company staff, from cleaners, operators, union reps, up to director and stakeholder level.
Development Engineer AECI Sasolburg 4 years
* Managed process improvement projects and staff at a large chemical plant.
* Led teams of up to 25 artisans on 5 one month chemical plant turnarounds, completing all work to schedule.
* Ensured all plant equipment complied with environmental, health and safety requirements.
* Commissioned all the motors, pumps, stirrers, fans, agitators and associated equipment on a 25 ton/day cyanide plant.
Mechanical Services Superintendent, Caltex Oil Refinery, South Africa, 8 month contract
* Managed the overhaul of all the turbines, compressors, pumps and associated equipment on an oil refinery during an 8 week shutdown. Led a team of 80 personnel.
* Ensured that critical path activities were finished on schedule and had all the equipment back on-line, on-time.
* Multiple troubleshooting situations resolved quickly using techniques, such as brainstorming, DESIDE, best case – worst case, root cause analysis.
* After the shutdown, responsible for day-to-day operation of all rotating machinery at the refinery, managing the mechanical workshop and the equipment monitoring staff of 46 personnel.
* Dramatically improved maintenance repair times by 60% and significantly reduced overtime.
* Improved communication and relations between maintenance and production personnel resulting in mutual respect and improved operating efficiency.
Manager, KPMG 3.5 years
Implemented Oracle process and discrete ERP manufacturing applications in three different companies, including 3rd party maintenance software. Experienced with both discrete and process modules.
Audited 14 software projects for State of North Carolina, providing ...
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