Production Manager
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I have 15+ years successful hands on experience and solid based understanding of manufacturing industry operations and practices.
JUNE 2023- DATE: KITENGELA GLASS LTD- ONGATA RONGAI KENYA
This is glass recycling company located in the outskirts of Nairobi City making vases, chandeliers, drinking tumblers, jugs, glass beads, garden jewelry hangings and furniture all made from recycled glass.
Ø Plan and oversee daily, weekly and monthly production schedule ensuring efficient resource allocation and timely output
Ø Develop a training schedule and follow up with execution and implementation to ensure engaged and process sound team.
Ø Prepare, analyze, and submit accurate and timely production reports, track performance and propose measures to remove any bottlenecks to improve production
Ø Manage the allocation of resources, including personnel, materials, and equipment, to optimize production schedules
Ø Develop and implement production strategies that reduce waste while improving quality and customer satisfaction
Ø Ensure compliance with existing health and safety standards
Ø Perform regular audits and inspection of machinery and production lines to ensure availability and reliability
Ø Foster cross functional collaboration with other departments to streamline production processes
Ø Identify opportunities for process improvements and implement solutions to enhance efficiency, reduce costs, and minimize waste
Ø Manage inventory and coordinate with operations/logistics to prevent shortages
Ø Conduct regular inspections of machinery and equipment, coordinating maintenance activities to prevent downtime
Ø Conduct performance reviews, training programs and one on one sessions with staff
Ø Foster a positive and productive work environment, promoting teamwork and employee engagement
Ø Doubled output in 12 months through process optimization and blowers training, justified this leading to capex investment in an extra new furnace
Ø Trained and cross trained 16 glass blowers across 4 processes reducing single individual dependence, improving line flexibility and cover to 95% + in case of absence or emergencies
Ø Maintained zero LTI in 2 years from 2024 through proactive safety audits, operator safety trainings, daily toolbox talks, near miss reporting and LOTO compliance, signage’s and OPLs and gaps closures.
Ø Scaled operations through facility expansion and head count growth from 46 to 100+ exceeding revenue target by 118% in FY2025
Ø Delivered 100% materials availability for 24 months through safety stocks optimization and daily/weekly cycle counts and reorder triggers.
JULY 2021-MAY 2023: LEAN ENERGY SOLUTIONS LTD - MAAI MAHIU KENYA
This company converts loose biomass into compact, high density, and low volume lumps by mechanical compression called Lean BRIQS which is a ready substitute for coal/wood in industrial boilers and brick kilns for thermal applications.
Ø Oversee daily plant operations with a focus on safety, quality and efficiency
Ø Coordinate production planning and scheduling and resolve bottle neck
Ø Implement process improvements reducing production costs improving efficiency
Ø Development and maintenance of SOPs ensuring consistency and compliance across all shifts
Ø Ensure cross team coordination
Ø Monitor production KPIs and report to Operations Manager for informed decision making on operational adjustments
Ø Support in the recruitment, training and development of new staff improving team performance and retention.
Ø Increased production 150% from 10T/day to 25T/day maintaining 98% quality rate by adding another production line, operators training, AM/PM and structured shift change overs.
Ø Maintained zero LTI in 2 years through proactive safety audits, operator safety trainings, daily toolbox talks, near miss reporting and LOTO compliance.
Ø Maintained zero product recall in years by strengthening in process QC checks across 3 lines, close CAPA in 48 hours, operators training on defects detection and stricter batch release criteria.
Ø Improved machines availability and reliability through AM and structured PM reducing unplanned downtime and having stand by line.
Ø Raised service level to 98% in 4 months by restructuring shift handover and tightening production-dispatch coordination.
JULY 2019-JUNE 2021: PERSEA OIL AND ORCHARDS LTD- THIKA KENYA
This company produces the finest cold press Organic Extra virgin and crude avocado oils.
Ø Supervise day-to-day production activities to ensure adherence to the production schedule
Ø Ensure compliance with Safety, Health, Environment and Quality (SHEQ) procedures.
Ø Maintain hygienic conditions across the warehouse and production areas.
Ø Assign daily tasks and monitor completion of operational activities.
Ø Ensure fruit handling and production activities meet quality standards as guided by the quality team.
Ø Ensure smooth transfer of fruits and materials between the warehouse and processing areas.
Ø Carry out line tours to monitor production flow and escalate equipment, staffing, or operational issues to the Operations manager.
Ø Ensure processing activities follow SOPs and quality requirements.
Ø Report on various metrics across production and warehouse operations.
Ø Provide daily updates on fruit intake, warehouse operations, and production activities.
Ø Escalate operational issues affecting production or warehouse performance.
Ø Ensure FIFO is followed when issuing fruits to production.
Ø Support stock reconciliation between the warehouse and production teams.
Ø Supervise production and warehouse staff, forklift operators, clerks, and casual workers during the shift.
Ø Support implementation of the Food Safety Management System (FSMS) during daily operations.
Ø Monitor fruit waste and damage during offloading, sorting, and processing.
Ø Ensure waste is recorded and handled according to procedures.
Ø Escalate abnormal loss levels to supervisors
Ø Reduced avocado off loading and sorting waste by implementing accountability checks, operator sign off and damage tracking reducing damage and losses
Ø Implemented AM and PM reducing unplanned downtime 35% and increasing OEE from 68% to 80% in 4 months.
Ø Maintained zero safety incident in 2 years by enforcing LOTO, daily toolbox talks and RCA on all near misses
MAY 2013-JUNE 2019: MARS WRIGLEY CONFECTIONERY- ATHI RIVER KENYA
This company is a proud producer of the popular chewing gum, Candy and confectioneries.
Ø Develop and implement daily production plans based on demand forecasts
Ø Managed raw materials and WIP flow using SAP MI01, MI04, MI07maintaining inventory accuracy at 98.5%
Ø Ensure availability of raw and packaging materials
Ø Supervise production staff, assign duties and monitor shift performance
Ø Drive efficiency, food safety compliance by monitoring every KPI
Ø Train, coach, mentor and guide team members
Ø Liaise with other departments to ensure efficient process flow.
Ø Ensure products meet quality and regulatory standards
Ø Enforce hygiene and food safety procedures
Ø Investigate and resolve quality issues
Ø Ensure correct sealing, dating, and labeling
Ø Enforce FIFO principles
Ø Monitor machinery performance, report faults and coordinate maintenance while supporting preventive maintenance schedules
Ø Identify skill gaps and organize trainings, retraining and cross training
Ø Ensure the production target is safely met on time and quality
Ø Oversee daily production processes, review all SOPs, GMP/GHP/ HACCP procedures
Ø Enforce workplace safety standards by ensuring PPE usage and conduct safety inspections
Ø Analyze production data and reduce bottlenecks, minimize waste and product reworks/rejects
Ø Investigate any variances in raw material stock and yield and document any resolutions/actions
Ø Develop and enforce GMP/GHP to ensure consistent quality of products, develop action plan to eliminate all root causes to guarantee product quality
Ø Obtain feedback from customers and marketing and sales staff regarding product quality and act on them
Ø Ensure all AM activities are carried out on time and work with Engineering to close all actions to minimize downtime
Ø Ensure sanitation schedule is followed and records are maintained
Ø Oversee the recruitment process, interviews, training and induction of new staff
Ø Implement, oversee and maintain the ISO 22000 Food safety Management system and Halal and other certifications
Ø Overhauled all SOP, OPL and CCP documentations to match new process flow cutting operator errors and passing start up audits with zero non conformities
Ø Led 100% operator transition to new factory in 3 months with zero production disruption through targeted training and phased transition
Ø Recognized for great team leadership 2018 for maintaining 0 LTI, 98% OTIF, 95% team engagement score and zero quality escapes in 12 months.
Ø Implemented cross training program for 33 operators increasing multitasking coverage to 90%, eliminating single individual dependencies, reducing unplanned downtime by over 25%, increasing line efficiency by 15% and improving team engagement.
Ø Working with others, redesigned the shift pattern for 99 operators to eliminate unplanned OT, stabilizing line efficiency at 85%+, cutting labor cost by 18%, maintaining 98% service level and reducing fatigue related incidents
Ø Developed and implemented standardized startup / shutdown procedures for sugar line eliminating recurring start up jams and reducing start up time by 20%
Ø Reduced production related incidences by 95% cutting incidence from 40 in 2018 to only 2 in 2019 in through daily in process checks and 48 hour CAPA closure.
Ø Implemented waste segregation program achieving 100% segregation compliance and zero waste to landfill by standardizing sorting process, training 99 operators and launching color coded segregation system
MARCH 2012-APR 2013: DEEPA INDUSTRIES LTD NAIROBI KENYA
This company is the largest manufacturer of potato snacks and spices in
Kenya. Potato Snacks include Crisp, Chevda and Sticks. Other snacks
Include popcorn, extruded snacks, peanuts, and fried peas.
Ø Maintain a safe and healthy production environment
Ø Provide objective directions and leadership in prioritizing and making decisions of allocating human and materials resources
Ø Work with other departments in creating and revising SOPs, training manuals to improve and optimize operations.
Ø Manage and evaluate entire production process
Ø Contribute to production planning and budgeting
Ø Role model and embed operations mindsets and behaviors into the team to ensure safe and efficient production of quality products.
Ø Lead and monitor quality assessments to ensure customer satisfaction
Ø Train operators and technicians to identify root causes, implement solution and formulate actions to address non-conformities.
Ø Supervise the entire production team
Ø Escalate issues and seek support needed from production manager
Ø Cut bag reel waste by 75% through SOP optimization and operator training improving material yield without affecting packing integrity
Ø Led a 6 cross functional team to install and commission shrink wrapper machine on time and 8% under budget enabling 20% increase in packaging throughput with zero safety incident.
Ø Introduced staggered breaks to keep lines running cutting downtime by 45mins / shift improving daily output by 60 units without adding labor
BACHELOR OF EDUCATION TECHNOLOGY ( ELECTRICAL AND ELECTRONICS TECHNOLOGY) FROM MOI UNIVERSITY
