Fiona Nxumalo

Manufacturing Excellence Expert with a strong working knowledge and experience in Six Sigma black belt and World Class Manufacturing (WCM) Methodology. Proven ability to facilitate and implement continuous improvement tools such as 5S, Standard Work, Kaizen Events, Reliability Maintenance, Autonomous Maintenance and Total Quality and Process Control.

WCM Consultant at Tetra Pak (2025-11 – Present)

• Manage and lead delivery of solutions, by managing scope and delivery team within agreed timelines and to the required quality
• Manage business result of projects delivered and managed by self
• Sell Expert Services projects and solutions, support sales on non Expert Services solutions
• Calculate and develop customer opportunity analysis
• Deliver customer training and coach customer management
• Provide Key Account teams with customer insight and quantification of potential deliverable value
• Support development of new Expert Service product/solution content and methodologies

Market Manufacturing Excellence Expert at Nestle (2021-07 – 2025-10)

• Integrate TPM with other NCE practices (Foundations & Lean) and Functional Systems (e.g. NIMS) & CO-Manufacturing departments (e.g. NWSM, NGMP, NSAM)
• Coordinate the support from external consultants if applicable
• Ensure that TPM work is impacting both results and the culture change towards the market vision
• Communicate TPM activities and results to Steering Committee in the Market/Region
• Coach Market Steering Committee in Governance routines to manage TPM implementation for business results
• Communicate / report the TPM activities and results to the Cluster Manufacturing Excellence Manager
• Establish adequate competencies for Manufacturing Excellence in the Market
• Stewards, trains, supports and coaches Factory Leadership Teams in the NCE in Manufacturing competencies (e.g.GA, FI, LVS, AM) and applicable manufacturing standards
• Develops competency of Market T&P team, supporting them to apply methodologies to improve and sustain results (e.g. all NCE methodologies, Value Added Activities, Workload studies, etc.)
• Supports the development of the career succession planning of the Market Manufacturing Excellence community
• Drive the TPM implementation by supporting the Factory Managers, Manufacturing Excellence Business Partners and Market Pillars Leaders
• Lead and coach the Market Pillar Leaders. Motivate and empower people through positive attitude
• Stimulate change in traditional mind set towards 'Zero'
• Support the factories in resources availability
• Support the Market Manufacturing Excellence Manager on organizing TPM Study Tours and Workshops
• Coach the factory manager and Manufacturing Excellence Business Partners in terms of TPM and NCE Practices
• Lead the Promotion Campaign for TPM in the Market /Region
• Coordinate / participate in defining and executing the market TPM masterplan to deliver Business needs
• Promote and support cross-fertilization of ideas, knowledge, standards and improvements across factories within Market & outside Market
• Integrate the pillars to avoid silo working
• Ensure an overall understanding of the different TPM pillars and how they integrate through the TPM master plan to deliver the improved results
• Calibration of assessments and step/phase audits between factories to assure thorough TPM implementation ensure alignment with Reference Guide and Market Strategy
• Assessment of the implementation progress/ factories

Continuous Improvement Manager at Saint Gobain (2014-09 – 2021-06)

• Led, facilitated and co-ordinate teams in the application of focused improvement tools (DMAIC)
• Led kaizen event that was able to reduce production scrap by 25% due to facing defects on rolls
• Established a visual management which resulted in improved shift handover meetings
• Established the Total Quality and Process Control (TPQC) pillar, Reliability pillar, Autonomous Maintenance pillar, Focused Improvement pillar, People Development pillar which assists management to develop strategy to improve plant performance
• Designed and implemented a standard work system in the plant which reduced safety incidences, improved operator moral and ensure management spends 70% of their time in the plant
• Focused on teaching the operations staff on the use of the WCM tools (5S, quick kaizen, 5 why analysis, EWO, 5W+1H, SOPs, tagging, etc.) and they became contributors in identifying top 3 issues for resolution
• Cascaded annual plant policy deployment to all levels
• Developed down time management system for artisans focusing on top hitter Pareto analysis to develop corrective action plans
• Led machine reliability project on the fiberize gas train to reduce breakdowns to zero
• Led kaizen event to eliminate production scrap by 15% due packaging problems at the packaging machine
• Ensured that the plant uses shared learnings and contributes its own shared learnings to the business
• Use excels statistical tools to track process controls, determine process capability and keep management informed on key process indicators
• Facilitated structured communication program in the production floor, daily production meetings (level 2) which roll up to management objectives
• Create and trained SOPs, forms and standard work for operators
• Implemented cost deployment model to prioritise losses in the plant
• Developed 5-year route map for WCM to gold
• Audit the WCM system to ensure integrity is maintained

Manufacturing Development Manager at SABMiller (Swaziland Beverages) (2012-02 – 2014-08)

• Trained and guided the employees in the application of WCM tools
• Led, facilitated and co-ordinate teams in the application of focused improvement tools (DMAIC)
• Ensured continuous improvement of WCM tools by implementing shared lessons
• Ensured that the WCM champions are fully conversant with the system through training and coaching
• Conducted and moderated regular assessment using the GEM to assess department/plant maturity in the WCM work practices
• Facilitated and guided the WCM route map towards the WCM maturity and effectiveness
• Preserved the integrity of the system through regular auditing
• Used value chain map and improvement tools to identify potential cost saving projects
• Conducted appropriate benchmarking exercise to gauge plant/departmental improvements
• Ensured the integrity of the DMAIC problem solving process
• Led projects to improve plant performance
• Facilitated the SOP learning process
• Provided industrial engineering support

Process Capability Engineer at Kraft Foods (2011-01 – 2012-01)

• Managed the 3 process technicians responsible for candy, bubble-gum and chocolate areas
• Collected and analysed of data using excel statistical tools required to make improvements in the plant
• Supervised new product development process in the plant
• Investigated and problem solved process problems using problem solving tools (kaizen, 5 why. 5W+1H)
• Ensure that the material balances reconciled to the BOM
• Ensured that the equipment specification and capabilities were optimised
• Ensured current and relevant SOPs are in place and were being followed by doing PJO
• Assessed the safety and environment issues
• Conducted bi-annual reviews with process team

Distillation Foreman at Royal Swaziland Sugar Corporation (2007-08 – 2010-12)

• Managed a team of 10 personnel per shift
• Ensured that the weekly production plan is developed, and it is adhered to
• Ensured daily targets are achieved and actioned plans developed to close gaps
• Ensured that daily production quality checks are conducted, and deviations are corrected
• Ensured the anhydrous plant operated efficiently
• Ensured that the maintenance and cleaning of the equipment was adhered to
• Managed a departmental budget
• Ensured the customer receives the products on time and in full at the correct quality
• Ensured that the effluent treatment operated as per standard with no environmental incident
• Ensured that the calibration of all instrument's equipment occurred as per schedule
• Problem solving quality, cost and productivity issues

B.ENG. (Hons) in Chemical Engineering – University Of Pretoria (2007 – 2007)

B.ENG. in Chemical Engineering – University of Pretoria (2008 – 2008)

Focus Improvement, Reliability Maintenance, Autonomous Maintenance, TPQC, Cost Deployment, Change Management, Facilitation and Coaching skills – Saint Gobain Academy (2014 – 2016)

DMAIC, 5S, Reliability Maintenance, Teamwork pillar, Standard Work – SABMiller Academy (2012 – 2014)

Six Sigma Green belt – Aveta Business Institute (2021 – 2021)