Ofem Okoi

Passionate, reliable result-oriented and data-driven Industrial Process Technologist with 20 years of experience driving operational excellence, process optimization, manufacturing systems, production planning for operational efficiency improvement across FMCG manufacturing sector aim at reducing waste and improved OEE. Strong expertise in Lean Manufacturing, six sigma, workflow optimization, capacity planning and supply chain analysis. Proven track record of building continuous improvement culture across all functional teams enhancing workflow productivity that will lead to improved production efficiency and reduction in cycle time.

Analytically inclined to identifiable gaps between high-impact shop floor teams and management strategic plans that will promote up-skilling and succession planning for competitive and sustainable growth. Influential in team management/relationship building and a competent team player who is adaptable and always open to learning new skills especially in a new environment.

Packaging Operators' Team Leader at NIGERIAN BREWERIES PLC (1997-07 – 2001-09)

Production team leader driving production productivity in volume alongside Safety and Quality in a high-technical speed packaging operations environment. Highly skilled in line balancing and changeover, production analysis, SOP enforcement, motivating teams to meet production daily target/KPIs positively. Reports to line Senior Supervisor.

• Consistently hitting between 97% - 100% team production daily target while maintaining <0.5 defect rate.
• Achievement of 1000 days without lost day injury, zero incident and zero accident.
• Reduced changeover time by 30% through standardization of changeover procedures and training of all operators.
• Increase in volume production through CILT, 100% tagging and 95% - 98% de-tagging exercises.
• Consistent collaboration with PM team breakdown analysis, schedule maintenance and knowledge transfer drastically reduced MTBA, MTBT by 35% of speed loses.

Packaging Maintenance Team Leader at NIGERIAN BREWERIES PLC (2001-09 – 2006-02)

Hands-on maintenance leader driving equipment reliability, availability and performance. Coached maintenance team on PM approved systems and structures in manufacturing environment and improved OEE by 25% with emphasis on strict compliance to safety Standards.

• Unplanned downtime reduced from 42% to 15% across the 3 lines of production.
• First line basic maintenance training improved MTBT and MTBA 42% (Knowledge Transfer – Step 4).
• Routine inspection on spare parts supplied reduced maintenance cost by 20%.
• Machine reliability improved OEE from 79% to 92% within 12 months.

Total Productive Management Assistant (TPM Office) at NIGERIAN BREWERIES PLC (2010-08 – 2018-09)

Constantly driving OEE improvement through TPM pillars, strong training facilitator on lean manufacturing and tracking TPM matrix for building operators' ownership and maintenance reliability thereby reducing production loses (Breakdown, Minor stops, Reject, Rework, Set-up time & Adjustment, Changeover that will improve performance and productivity. Strategic focus on Production, Maintenance, Logistics and all materials, products and spare parts inventory management systems.

• Lean Manufacturing transformation impact on the three production lines improved OEE from 84% to 92% within 6 months.
• Facilitated and mentored 50+ cross-functional kaizen shop floor teams generated ₦143M annual savings in 2014 through waste reduction and elimination.
• Developed and Conducted CI training programs for over 108 technical employees.
• 5S across inventory and warehouse operations improved space utilization by 15% OTD by 30%.
• 350+ improvement ideas submitted to TPM office per year due to CI culture change.
• Reduced safety incidents by 65% with achievement of zero lost-time from injuries 1008 days in Aba brewery.
• Achieved 98% compliance rate on Aba brewery Process Audit for 3 consecutive years.

Process Improvement Expert at ARU AND GEE NIGERIA LTD - CONSULTING (2019-02 – Present)

Lean manufacturing practitioner leading in rapid improvement through kaizen events and other data-driven problem solving techniques in manufacturing operations. Skilled at engaging cross-functional teams to eliminate or reduce waste and improve process flow of operational excellence.

• Implemented and supported lean manufacturing activities and tracked improvement metrics for management review.
• Designed new work instructions and standards thereby bringing down training time by 45% and improving first time right on quality.
• Implemented the use of SPC and DMAIC in solving quality issues and we reduced defects by 30% and also saved ₦154 million in 12 months from consumer complaints.
• Designed and implemented Improvement suggestion system generating over 200 ideas per year.
• Facilitated training on breakdown and safety RCFA differentiating functional failure from failure mode and reduced analysis time by 50% with 95% accuracy.
• Implemented Visual Management System at the spare parts store and finished product warehouse and reduced logistics search time by 15%.
• Designed 5S and visual management system at the Logistics department for decent and accurate parking of trucks and improved delivery time by 18% and lead time by 8%.
• Introduced daily control system meeting of 20 minutes between management and staff across all departments for priority setting and effective time management.
• Supervised real time data capturing systems for MTBA, MTBT, MTBF and MTTR devoid of assumptions and time wasting during analysis.

– St. Patrick's Technical College

Bachelor of Technology in Project Management Technology – Federal University of Technology, Owerri