Expert in International Industry Specialist in World Class Manufacturing
Expert ID: 729210 South Africa
Expert has excelled in the area of performance improvements for manufacturing plants. Using a host of "productivity tools," Expert has in his past three projects provided his clients with;
1) a 300% improvement for a joint venture operation between two of the biggest names in the automotive business.
2) a 770% improvement in manufacturing performance for World leaders in the catalytic converter business
3) a 500% improvement in packing capacity for a chemical packing plant in Europe.
Expert has both automated manufacturing lines for his clients and also taken automated lines and added a manual element to them, considerably reducing costs and improving product quality.
Expert has very successfully undertaken no less than eight relocation projects. These have ranged from manufacturing plants with more than 600 employees, to major projects involving more than 300 project dedicated staff, the designing and building of two new factories on the new site and a R30 million budget. Expert has with the relocation projects also undertaken the complexities of consolidating manufacturing plants under a common roof. As a result of exceptional planning and project coordination, Expert has on more than one occasion been able to keep a clients plant running throughout the relocation project.
Expert has undertaken several projects requiring either the design or the re-design of manufacturing plants.
In designing a new plant Expert does not only cover a clients current manufacturing requirements, but also likes to build into his designs the clients future requirements. This way when the client is ready, future additions to manufacturing lines to increase production levels can be made with the minimum of disruption to the production
Expert has experience in all of the following industries:
Chemical manufacturing (catalytic converters)
Manufacturing across multi site operations
Operations (logistics) across multi site locations
Logistics and Distribution
Supply Chain Planning
IT Hardware and Software solutions
Fashion Garments and General Clothing
Utilities and Public Services
Fibre cement and moulded products
Armoured and Military Defence Vehicles
Expert's client, a major manufacturer of catalytic converters in
Europe, was experiencing real problems in both Quantity and
The production volumes required to meet the client’s
market were way in excess of their manufacturing capability.
To further complicate matters, the client had a purpose
built “sleeving” plant which used the same “sleeving” processes
as their competitors.
The results were a massive loss in potential sales and extremely
poor quality as a result of the manufacturing method which failed
to take into account some of the unique properties of the client’s
Expert provided the client with a World first for their unique
manufacturing requirements (for which they have applied for a patent)
which solved their quality problems 100%. Then with some expert
reengineering of their production processes, Expert gave them a 770%
increase in manufacturing levels.
Given, how many scientists had tried to solve the quality problems
and how many “experts” had tried to improve the production levels,
the client believes Expert's work is exceptional.Expert's clients here are two of the biggest names in global automotive
manufacturing. In a Joint Venture with their manufacturing plant based in
Africa, the JV was on the verge of collapse as it was totally unable to
meet the demands of a booming European market.
Realising the impact this would have on both companies, experts
were called in from China, South America, England and the US (20 in all).
Their task was simply to increase production levels to meet the European
market requirements (this would mean an increase in the region of 250%).
After three months the results from the 20 experts were almost non-existent.
Extremely relevant to the nature of this project was the fact that, because
of the critical supply situation, all performance improvements had to be
made while keeping the plant running 24/7.
The 20 man team was replaced with only a 2 man team, with Expert as the Project Leader and one other assistant to Expert. From here they were
able to completely re-design the manufacturing plant, implementing the
complex changes while keeping the plant running 24/7.
The end result was a 300% improvement in production performance, a
successful Joint Venture, R500 million in increased turnover per annum
and a happy European market.I have just completed a two year contract as the industry specialist for the management and performance improvement of the manufacturing industry in Kenya, this was undertaken for the largest bank in Kenya, based in Nairobi. This position was created as part of the Kenyan Vision 2030 to make Kenya the economic hub of East Africa. As part of the leadership of the Vision 2030, Dr James Mwangi, the CEO of Equity Bank, headhunted industry specialists from around the globe. This enables the bank to not only provide financial services to its clients, but industry specialist knowledge that no other bank has. In my role in the development of the manufacturing industry in Kenya, I mentored CEO’s Directors and GM’s on how to manage their manufacturing operations effectively (from both the engineering and management perspectives), in order to compete in an emerging global economy
|Year: 1986||Degree: BSc||Subject: Set and marked BSc papers in Production Processes and Work Measurement||Institution: University of Natal, Natal, South Africa|
|Year: 1978||Degree:||Subject: Industrial Engineering and Work Study||Institution: Croydon College of Design and Technology|
|Years: 1994 to 2014||Employer: Industrial Consulting Services||Title: Executive Manufacturing Consultant||Department: Manufacturing||Responsibilities: Expert is responsible for all national and international consulting assignments in the manufacturing sector.|
|Years: 1992 to 1994||Employer: Progress Industries||Title: General Manager||Department: Progress Manufacturing Plant||Responsibilities: As General Manager of the main Progress manufacturing plant Expert managed a plant with over 600 employees with departmental managers from, production, planning, HR, design, industrial engineering, purchasing, raw materials stores, packing and despatch all reporting directly to him.
The plant had 10 production lines with several pre-production line preparation facilities.
|Years: 1988 to 1992||Employer: Lesotho Clothing||Title: Operations Director||Department: Operations||Responsibilities: As Operations Director Expert was responsible for the entire operations division of the company. This covered the supply chain, purchasing, design department, quality control, logistics, transport division, production planning, supplier and customer relations, raw materials and warehousing across a multi site operation.|
|Years: 2014 to 2016||Employer: Equity Bank||Title: General Manager||Department: Manufacturing||Responsibilities: I have just completed a two year contract as the industry specialist for the management and performance improvement of the manufacturing industry in Kenya, this was undertaken for the largest bank in Kenya, based in Nairobi. This position was created as part of the Kenyan Vision 2030 to make Kenya the economic hub of East Africa. As part of the leadership of the Vision 2030, Dr James Mwangi, the CEO of Equity Bank, headhunted industry specialists from around the globe. This enables the bank to not only provide financial services to its clients, but industry specialist knowledge that no other bank has. In my role in the development of the manufacturing industry in Kenya, I mentored CEO’s Directors and GM’s on how to manage their manufacturing operations effectively (from both the engineering and management perspectives), in order to compete in an emerging global economy|
|Years||Country / Region||Summary|
|Years: 2009 to 2009||Country / Region: Denmark||Summary: Expert undertook 2 projects in Denmark for a World leader in chemical manufacturing and catalytic converters for the automotive industry.|
|Years: 2007 to 2008||Country / Region: South Africa||Summary: Expert undertook a major turnaround project for 2 world leaders in the automotive industry.|
|Years: 1990 to 1990||Country / Region: Lesotho||Summary: Expert undertook a project for a major Lesotho Clothing Company.|
|Years: 1991 to 1992||Country / Region: Zimbabwe||Summary: Expert undertook a project for a major Zimbabwe Clothing Company.|
|Years: 1979 to 1979||Country / Region: Ireland||Summary: Expert undertook a project for the Guinness company at their main bottling plant in Dublin Ireland.|
|Years: 2014 to 2014||Country / Region: Rwanda||Summary: Company requiring over $100 million|
|Years: 2014 to 2014||Country / Region: Kenya||Summary: Industry Specialist in Manufacturing|
|Associations / Societies|
|IIE Institute of Industrial Engineers (USA);
AMS Institute of Management Services.
|Publications and Patents Summary|
|Expert has authored 2 books.|
Fields of Expertise
international manufacturing, world-class manufacturing, manufacturing process optimization, manufacturing productivity, automated manufacturing, turn key, facility relocation, industrial relocation, plant relocation, manufacturing site evaluation, manufacturing site selection, industrial plant design, manufacturing facility design, manufacturing facility, automobile manufacturing, chemical plant manufacturing, clothing manufacturing, manufacturing, manufacturing quality assurance, manufacturing quality control, lean manufacturing, chemical industry, high volume, low cost product assembly, turn key, automated machinery, manufacturing cost control, manufacturing cost analysis, manufacturing execution system, manufacturing model, manufacturing simulation, continuous flow manufacturing, food product manufacturing, manufacturing planning computer system, glass manufacturing process improvement, manufacturing documentation system, manufacturing cell performance analysis, manufacturing cell design, manufacturing process development, manufacturing information system, manufacturing technology, food processing good manufacturing practice, manufacturing systems analysis, automated equipment development, chemical plant, computer-aided manufacturing, manufacturing systems modeling, manufacturing software, design for manufacture and assembly, automated machine design, manufacturing control, capacity planning, industrial benchmarking, manufacturing cell