Professional Profile
An Experienced Industrial Engineer with 8 years’ working experience at mid management and consultant level. Proven working experience in project management, maintenance management, production management and SHEQ management in various production, engineering and logistics operations at various organisations including Xstrata Alloys (Ferrochrome Mining Operation), Widney Transport Components, Mercedes Benz S.A., Johnson Matthey SA and Eskom. Successfully managed and coordinated various plant maintenance projects and maintenance shutdowns, new automotive part introduction projects, supply chain optimisation and cost reduction projects .
Sound knowledge of quality management systems development and implementation. Adapts well to understanding and implementing new systems and has a firm focus on team building to ensure given targets are met. Background in industrial engineering has provided various tools to improve productivity and balance constraints to achieve optimal performance.
Managed various skilled and semi-skilled teams between 4 and 10 employees. Experienced in establishing and maintaining good supplier / contractor relationships and achieving timely delivery of deadlines. Good planning, communication, prioritising, coordination, interpersonal, self-management, performance management and project management skills. Extensive exposure gained to the Mercedes Production System (MPS), ISO 9001, ISO 1400 and OHSAS 1800 implementation and maintenance of these management systems, strategy implementation, financial planning and budgeting.
Education
2012
University of Pretoria
B.Sc (Hons) Applied Science in Industrial Systems
2010
University of Johannesburg
B-Tech Engineering Industrial
2006
Tshwane University of Technology
N.Dip Engineering Industrial
2000
Zinniaville Secondary School, Rustenburg
Grade 12 (Matric)
Professional Courses / Training
• ISO 9001 Awareness
• ISO 9001 Lead Auditor
• SHEQ Integration Based on ISO 9001, ISO 14001 and OHSAS 18001
• FMEA and Control Plans
• AutoCAD Advanced
• HIRAC – Hazard Identification, Risk Assessment and Controls
• BBS – Behavioural Based Safety
• Advanced Lifting Equipment
Computer Skills
• Microsoft Office (Word, Excel, PowerPoint)
• SAP
• Microsoft Visio (Process Mapping – Simulation Software)
• Google Sketch Up (3D CAD Simulation Software)
• AutoCAD (Advanced) • MES – Manufacturing Execution System (loading part specifications, tolerences, etc.)
• PDT (Part Data Tracking)
• MES – Statistical Process Control
• NWA Quality Analyst
• Achiever Plus (Electronic QMS)
• ISOsoft (Electronic QMS)
Areas of Expertise
Business Management Systems:
• ISO 9001 – quality management system.
• ISO 14001 – environmental management system.
• OHSAS 18001 – health and safety management system.
Lead Auditor:
• ISO 9001 QMS Lead Auditor.
Project Management:
• Project planning and documentation.
• Maintaining project resources and costs in Microsoft Project for shutdowns and other projects.
• Time studies for shutdowns and projects in order to minimise downtimes and work within time constraints for projects.
• Managing cross functional project times.
• Managing project priorities and deadlines.
Analytical tools and techniques:
• Determining variances.
• Break even analysis.
• Pareto analysis.
• Theory of constraints.
Production Process Control:
• Production line setups.
• Time and method studies.
• Monitoring and measuring production processes using statistical process control (SPC).
• Process control charts.
• Root cause analysis.
Business Process Mapping:
• Mapping and streamlining processes to determine optimal solutions.
• Value stream mapping.
• End to end business process mapping.
• Business process re-engineering.
Continuous Improvement:
• Kaizen and various industrial engineering techniques for continuous improvement.
• Managing 8D investigations.
• Managing analysis and improvement groups.
• Train the trainer (Shop floor training).
• Executive sensitisations for new initiatives.
New Product Introduction Activities (APQP):
• Planning the AQPQ milestones.
• Coordinating document control for new parts.
• Ensuring project readiness for new part validations.
• Ensuring availability of new tooling for validations.
• Ensuring raw material availability for validation runs.
• Ensuring timely delivery of production part approval process to customers.
• Quality assurance of the entire AQPQ process.
• Facilitating customer/supplier audits.
SAP – Plant Maintenance:
• Creating and updating master data.
• Creating maintenance orders.
• Creating purchase requisitions.
• Maintenance history reports.
• Call out reports.
• Maintenance order backlog reports.
• Expediting reports.
• Changing maintenance plans.
SAP – Materials Management:
• Creating and updating master data.
• Creating and updating BOM’S.
• Creating purchase requisitions.
• Creating purchase orders.
• Purchase order history reports.
• Purchase requisition reports.
• Purchase order backlog reports.
• Expediting reports.
• Creating and updating routings.
Microsoft Excel:
• Manipulating data from SAP in MS Excel to generate graphs and tables for analysis purposes.
• General small database management in MS Excel (VLookups, IF statements, etc.).
Other:
• QMS development and implementation.
• Audit Schedule formulation
• Maintenance plan formulation
• Production plan formulation
Career History
2014 – 2015
3M South Africa
Woodmead, South Africa
Supply Chain Quality Manager
Responsibilities:
• Ensure that processes needed for the Quality Management System (QMS) are
established, implemented and maintained.
• Report to top management on the performance of the QMS and any need for
improvement.
• Ensure the promotion of awareness of customer requirements throughout the
organization.
• Liaise with the external assessment body on all matters related to the external
accreditation process.
• Managing and coordinating the supplier quality management program including
layered process audits and system audits as well as new supplier validation.
In more detail, the following specific actions relating to ISO 9001: 2008 were required:
• Ensure that a document control procedure is adopted to approve, review and update
all changes to critical documents within the scope of the QMS.
• Ensure that records are established and maintained to provide evidence that the QMS
is being followed and that there is a system in place for the identification, storage,
protection, retrieval, retention time and disposition of such records.
• Ensure that the performance of the QMS is reviewed at planned intervals to ensure its
continuing suitability, adequacy and effectiveness. This review means assessing
opportunities for improvement and the need for changes to the QMS.
• Ensure that Quality Objectives are set by top management for measuring the
performance of the QMS and that these are regularly reviewed.
• Ensure that all new staff are inducted into the requirements of the QMS related to
their own roles and responsibilities. Provide update training as necessary.
• Ensure that all suppliers used by the organization are selected, evaluated and reevaluated
and that records of this assessment are maintained.
• Ensure that top management undertakes periodic but regular assessments of customer
satisfaction and that consequent improvements are identified and implemented.
• Ensure that an internal audit programme is adopted to verify that the QMS conforms
to planned arrangements, QMS arrangements and is effectively implemented and
maintained. Ensure that appropriate action is taken when this is not the case.
• Analyse data on the effectiveness of the QMS and evaluate where continual
improvements of the QMS can be made. This includes data generated as a result
of monitoring and measurement and from other relevant sources.
• Co-ordinate continual improvements of the QMS, ensuring that evidence of corrective
and preventive actions taken are recorded and reviewed.
Major Projects
• Six Sigma training (Green Belt)
• Green Belt Project on Pallet Position reduction at distribution centre.
2012 – 2013
Eskom (Electrical Utility in South Africa)
Sunninghill, South Africa
Senior Advisor – Quality Assurance
Responsibilities:
• Reporting to the PMO Manager.
• Staff complement of 5 professionals directly reporting to me.
• Providing a professional advisory service to maintain an appropriate quality profile for Eskom through effective implementation of relevant quality strategies and policies and providing input to influence outcomes in the quality field.
• Developing and implementing a quality management system compliant to the requirements of ISO 9001 in various divisions / departments in Eskom by utilising general project management skills and methodologies under guidance from the Eskom Project Management Office.
• Developing, streamlining and optimising the quality management system to enable easy integration with other existing management systems in Eskom (namely environmental managements systems and health and safety management systems).
• Developing the following documents and processes:
– Quality policy.
– Quality manual.
– Document and records management procedure.
– Non-conforming product / process procedure.
– Internal audit procedure and internal audit plans.
– Corrective and preventative action procedure.
– Management review procedure.
• Performing other activities included but not limited to:
– Developing and implementing strategies and policies.
– Minimising risks to Eskom in terms of quality aspects.
– Liaising with stakeholders within and outside Eskom and participating in national organisation’s activities.
– Providing support to divisional responsibilities.
Major Projects
• ISO 9001 Implementation in Eskom.
Achievements
• Certification of the Entire organisation of approximately 40 000 employees in just under 2 years.
2010 – 2012
Johnson Matthey (SA)
Germiston, South Africa
Quality Assurance Coordinator
Responsibilities:
• Reporting to the Quality Manager.
• Staff complement of 10 directly reporting to me.
• Primarily coordinating the APQP process (Advanced Product Quality Planning) at JMSA.
• Coordinating new product introduction activities defined and governed by the automotive industry APQP process focussing on:
– Up-front quality planning.
– Determining if customers are satisfied by evaluating the output and supporting continual improvement.
• Implementing the 5 phases of APQP:
– Planning and defining program.
– Verifying product design and development.
– Verifying process design and development.
– Validating products and processes and providing feedback on production.
– Launching, assessing and taking corrective action.
• Planning.
• Designing and developing products.
• Designing and developing processes.
• Validating products and processes.
• Validating production processes.
• Implementing the 7 major elements of the APQP process:
– Understanding the needs of the customer.
– Providing proactive feedback and taking corrective action.
– Designing within the process capabilities.
– Analysing and mitigating failure modes.
– Verifying and validating.
– Completing design reviews.
– Controlling special / critical characteristics.
Major Projects
• New product introductions for Mercedes Benz, VW, Toyota, General Motors, Ford, Nissan and Renault.
Achievements
• Management Award for Significant Contribution towards environmental and cost initiative.
2009 – 2010
Johnson Matthey (SA)
Germiston, South Africa
Quality Assurance Engineer
Responsibilities:
• Reporting to the Assistant Quality Manager.
• Directly managing a team of 4 employees.
• Releasing quality assurance of production parts by using Statistical Process Control (SPC).
• Applying SPC in order to monitor and control processes to ensure conformity to product specifications and customer requirements.
• Monitoring and controlling quality processes to ensure that production processes operates at its full potential and doesn’t compromise customer requirements.
• Ensuring the process produces as much conforming product as possible with a minimum (if not an elimination) of waste (rework or trash).
• Using key tools in SPC, i.e.:
– Control charts.
– Continuous improvement.
– The design of experiments.
• Developing Continual Improvement Processes (CIP or CI) and activities to improve products and production processes. Focussing on incremental improvements over time to reduce defects and improve overall process quality and efficiency.
Achievements
• Promoted.
• Management Award for Extraordinary Contribution during labour unrest.
2009
Mercedes Benz (SA)
East London, South Africa
Industrial Engineer in Service Trainee (P2)
Overview:
• Internship: industrial engineering experiential learning program at MBSA East London Plant’s Logistics Planning Department.
Responsibilities
• Reporting to the Logistics Engineering Manager.
• Gaining exposure to the practical applications of various industrial engineering tools and techniques used in the supply chain cost reduction project in 2009.
• Developing packaging cost saving strategies.
• Streamlining parts/components database to identify cost saving opportunities.
• Performing data and statistical analyses.
• Researching and practical exercises to determine value of savings.
Major Projects
• Supply chain optimisation.
• Supply chain cost reduction through various packaging improvement activities.
• Optimisation of storage facilities and shipping consolidation methods.
• Analysing SAP data and identifying various optimisation opportunities.
• Teamwork with various Engineers in Germany and South Africa and working across varying time zones.
Achievements
• Supply Chain Cost Reduction Project in 2009 successfully resulted in a saving of approximately R15 million.
2008
Widney Transport Components (a division of Shatterprufe)
Alberton, South Africa
Industrial Engineer In Service Trainee (P1)
Overview:
• Internship: industrial engineering experiential learning program involving basic industry exposure to industrial engineering methodologies applied in a manufacturing environment.
Responsibilities
• Reporting to the Operations Manager.
• Gaining exposure to the following areas:
– Time studies on production lines.
– Kaizen – continuous improvement activities.
– Introduction to product development.
– Introduction to quality management.
– Introduction to project management.
– Introduction to production management.
– Planning, prioritising, coordinating and cultivating interpersonal understanding.
– Self-managing and communicating.
– Solving quality problems using root cause analysis.
– Purchasing and procuring associated with production planning.
– Managing supplier backlogs as input to production planning.
– Managing various WIP / inventory projects as input to managing inventory of obsolete parts.
– Supporting the SAP functions (knowledge of SAP – MM module).
– Knowledge of applicable mechanical plant equipment.
Major Projects
• Various small projects to gain project management and general management experience.
Achievements
• Successful completion of P1 learnership program.
2006 – 2008
Xstrata – Merafe Boshoek
Rustenburg, South Africa
Engineering Maintenance Planning Coordinator
Responsibilities:
• Reporting to the Engineering Manager.
• Directly managing a staff complement of 8 Artisans.
• Planning and coordinating a variety of scheduled maintenance activities for the Boshoek Sinter Plant.
• Performing specifically, planned maintenance and scheduled service visits by competent and suitable Agents (in-house and external), to ensure that items of equipment are operating correctly and to therefore avoid any unscheduled breakdown and downtime.
• Planning maintenance:
– Preventive maintenance.
– Condition Based Maintenance.
– Annual major planned maintenance shutdowns.
• Pre-planning and pre-programming maintenance and all future maintenance events on SAP system to manage production requirements, balance costs associated with production losses and costly breakdown of equipment as well as production backlog.
• Creating planned maintenance for every item of plant equipment separately according to manufacturer’s recommendation or legislation.
• Basing plans on equipment running hours for operational planned and date based maintenance for annual major maintenance requirements which were handled as projects.
• Managing the equipment maintenance system in the department to ensure availability and reliability.
• Performing reliability centered maintenance.
• Statistically analysing data.
• Planning, prioritising, coordinating and cultivating interpersonal understanding.
• Self-managing and communicating.
• Fully supporting the health, safety, environment and community related systems and projects in the plant.
• Supporting the SAP functions (knowledge of SAP plant maintenance system).
• Possessing knowledge of applicable mechanical and electrical plant equipment.
• Coordinating planned maintenance activities (operational and projects).
Major Projects
• 2006 Sinter Plant Annual Shutdown.
• 2007 Sinter Plant Annual Shutdown.
• 2012 ISO 9001 Implementation at Eskom
Key Strengths
• Management skills and leadership / mentoring capabilities.
• Results oriented – focused on productive and high-yield activities.
• Focused, self-motivated and target driven; determined to succeed.
• Training and development of quality in the organisation.
