N Mpanza

Results-driven Production Manager and Industrial Engineer with over nine years of progressive experience in high-volume, continuous manufacturing environments, including aluminium smelting, casting and cold rolling operations. Proven track record of leading production operations, improving asset utilisation, increasing manufacturing capacity, reducing operating costs and developing high-performing teams in demanding industrial environments. Experienced in end-to-end production management, including production planning and scheduling, resource allocation, workforce optimisation, operational execution, KPI management, cost control, quality assurance, equipment performance and continuous improvement.

Currently responsible for leading production operations, coordinating production plans with Planning, managing departmental manpower, driving operational recovery initiatives and ensuring production performance is aligned with business objectives. Strong capability in production line ownership, operational discipline and asset performance improvement, working closely with Engineering and Maintenance teams to improve equipment availability, reduce downtime, optimise utilisation and sustain production performance. Experienced in production recovery, breakdown investigation, root-cause analysis, preventive maintenance support, shutdown coordination and implementation of corrective and preventative actions.

Demonstrated ability to translate business objectives into measurable operational performance through production KPIs, daily management systems, performance dashboards, SPC, data analysis and structured performance reviews. Highly proficient in identifying bottlenecks, analysing process losses, improving throughput, reducing waste and implementing sustainable process controls. A recognised Operational Excellence and Continuous Improvement leader, with expertise in Lean Manufacturing, Six Sigma, Value Stream Mapping, Standardised Work, Statistical Process Control, 5S, Root Cause Analysis and process optimisation.

Successfully delivered initiatives that increased plant capacity by 22.3%, generated annual savings exceeding R78 million, improved material utilisation and eliminated significant sources of operational waste. Experienced in managing and developing frontline teams through structured performance management, coaching, training, accountability systems and workforce optimisation. Able to work effectively across Production, Engineering, Maintenance, Planning, Quality, Supply Chain, Finance and Procurement to achieve safety, quality, delivery, productivity and financial objectives.

Brings strong commercial awareness and financial discipline, with experience managing operational and capital expenditure, labour productivity, headcount optimisation, cost drivers and resource utilisation. Combines hands-on manufacturing knowledge with engineering and analytical capability to improve operational reliability, manufacturing efficiency and business performance

Production Manager – Aluminium smelter at Hulamin Operations – Richards Bay Casthouse (2024-06 – Present)

• Manage successful execution of recovery drive within the entire department
• Oversee the development of output-driven production plans and liaise with planning department such that optimal loading is achieved
• Ensure that the departmental manning with reference to level 1 is optimized and proper control measures are in place
• Drive continuous improvement initiatives and embed CI culture
• Coordinate training and development of the shop floor frontline employees
• Manage and control all human capital issues at Level 1 in the department
• Support shift leaders in executing their core responsibilities
• Ensuring that metal planning is done expeditiously including liaising with third parties and scrap recycling to optimize production plan
• Develop performance management systems for level 1 and shift leaders to ensure that labour productivity is improved and sustained
• Ensuring that key departmental KPIs on the shop floor are achieved in line with the business objectives
• Managing operational and capital expenditures

Process control and Improvement specialist, Reduction – Aluminium smelter at South32 – Hillside aluminium (2023-09 – 2024-06)

• Execute strategies to analyse performance and initiate improvement actions (e.g. dispatch control and analysis; plant / fleet statistical process control; production execution improvement)
• Adhere to standards and critical controls required to manage HSECQ and operational material risks, legal obligations and South32 and ISO Standards
• Conduct investigations of relevant Events. Execute the production equipment work strategies for SAP
• Assist to develop, review and maintain standard operating procedures to support the safe execution of production work
• Execute all duties in line with statutory legislation, and South32 standards and requirements
• Ensure timely and accurate reporting of all events and hazards and participate in workplace investigations or observations as required
• Contribute to building a cohesive working environment
• Actively participate in all people performance and development initiatives to ensure the team's performance meets the required standards

Process Technician, Cold Rolling - Aluminium at Hulamin Operations (2017-03 – 2023-09)

• Lead and apply Lean & Six Sigma methodologies (DMAIC, VSM, standardized work) to drive continuous improvement and process optimisation
• Conduct root cause analysis (5 Whys, Fishbone, KT, 6-Step) to resolve customer complaints and implement corrective actions
• Manage process control and quality systems (SPC charts, NCRs, QCVs, PCVs) to monitor performance and ensure compliance
• Drive quality improvement initiatives, including audits (ISO 9001, IATF 16949), FMEA, and control plans
• Perform data analysis and machine capability studies to improve product quality and support product development
• Develop and maintain SOPs, and train/coach operators to ensure adherence to quality and production standards
• Lead performance reporting and presentations (scorecards, OPP) to senior management
• Support production delivery targets, cost efficiency, and cross-functional collaboration
• Conduct safety risk assessments and job observations (PJOs) to maintain SHE standards
• Provide leadership support and stand-in management in a large-scale manufacturing environment

Engineering mathematics & Mechanical engineering drawing tutor at Durban University of Technology (2015-06 – 2019-06)

Bachelor of Business Administration in Business administration, process control and operations management – University of KwaZulu-Natal

Bachelor of Technology in Industrial Engineering – Durban University of Technology (2019)

National Diploma in Industrial Engineering – Durban University of Technology (2018)