Lunga Kula

ECSA-registered Chemical Engineer combining hands-on paint industry experience at Prominent Paints (PPG) with over five years of process engineering, root cause analysis, and quality systems leadership across FMCG and agro-processing manufacturing. Experienced in evaluating batch and material quality against supplier technical data and laboratory reports, handling hazardous chemicals, laboratory sample testing and scale-up, defect root-cause investigation, and driving measurable process, quality, and cost improvements. Track record includes zero-major-finding compliance audits, a 30% production capacity increase, waste reduction from 10.9% to 1.44%, a $75,600 efficiency saving, and elimination of 70 tons of contaminated finished goods.

IL6S Engineer at Mondelez International (2024-12 – Present)

• Led VSU trials across the Lunchbar and Wafer lines, ensuring zero major findings during audits through rigorous process documentation and compliance oversight.
• Design and define critical process parameters and centerlines, owning the Standard Work process for Centerline, CIL, MTBF and 12-Step KK, and tracking adherence to analyse variation.
• Analyse process variability and losses using root cause analysis, prioritising and eliminating them by designing systems and processes for the line teams.
• Custodian of process documentation, changes, and audits, including work instructions and centerline documentation; SME training/assessment resource for equipment, operational and raw material/packaging processes.
• Prepare loss analyses that direct continuous improvement priorities, resource allocation, and SQCDS reporting; ensure accurate BOM routings on SAP.

Production Coordinator / Process Engineer at Tongaat Hulett – Voermol Feeds (2021-08 – 2024-11)

• Coordinated and controlled the production manufacturing process across Feedmill, Block Plant and Pellet Plant, using the ABB System 800xA Batch system and IDF tracking system to maintain output and quality targets.
• Performed daily loss analysis and applied FI/MUV tools to identify, prioritise and eliminate production losses and waste across the plant.
• Investigated and resolved productivity, quality, safety and equipment-failure issues, partnering with the PM team to reduce breakdowns and improve reliability.
• Maintained SHEQ compliance and safety standards; served as Quality Management Representative and Quality Internal Auditor.
• Directed daily production planning across all plants based on product requirements; facilitated DMS and Gemba walks to prioritise improvement opportunities.

Lab Analyst / Chemical Engineering Trainee at Prominent Paints (PPG) (2017-01 – 2020-12)

The role was held during two separate periods: Jan 2017 – Jan 2018 and Jan 2020 – Dec 2020.

• Performed daily process checks, audit checks, and laboratory testing and quality control on paint batches, evaluating results against required specifications.
• Up-scaled R&D lab samples and developed rework plans for rejected batches, applying Root Cause Analysis to troubleshoot process and formulation issues.
• Conducted weekly FTR data analysis and built SPC charts to monitor batch and process consistency.
• Handled hazardous chemicals and treated hazardous sludge in the wastewater effluent plant; performed plant hygiene and cleaning procedures and coordinated internal and external hygiene audits under 5S methodology.
• Revised procedures and developed SOPs relating to factory practice; provided technical solutions to the production team and wrote reports on executed projects.

Bachelor of Technology in Chemical Engineering – Vaal University of Technology (2019)

National Diploma in Chemical Engineering – Vaal University of Technology (2018)