Dudu Radebe
Operations Excellence Manager
Estcourt, KZN
Summary
“I have 15+ Years Work Experience with various relevant and professional skills in the General & Project Management, Industrial Engineering, Managerial & Administrative, Financial & Budgets Management field. I possess a Master of Industrial Engineering, Master of Business Administration, BTech in Industrial Engineering, National Diploma in Industrial Engineering, Certificate in Project Management and MS Project, Senior Certificate (Matric) and a valid Code 10 Driver’s License. I am a self-motivated, enthusiastic, energetic, very active goal orientated person. I have acquired excellent communication and management skills and is accustomed to working under pressure without supervision. I am vibrant yet professional attitude and can communicate at all levels, of pleasant nature and well-groomed and I’m very results driven. I have got a no-nonsense but fair approach in my role as Manager. I’m prepared adapt to the working environment, work long hours under pressure and I do work well with other employees in a workplace.” Acquired Skills Personal Skills Professional Skills Good Communication Good Organizational, Managerial and Leadership Dedicated, Focused and Strong Attention to Details Independent worker and Team player Fast Learner, Self-Motivated and Good Assistant Problem solver and Maintains Confidentiality Works well under pressure and Minimal supervision General Management and Project Management Financial & Budgets Management Clerical & General Administration Operations Excellence and Leading and Managing Change (LMC) Industrial Engineering Health & Safety Customer Service / Client Relations
Overview
23
23
years of professional experience
2
2
years of post-secondary education
2
2
Certifications
Work History
Area Industrial Engineer
Dunlop Tyres
Ladysmith
07.2004 - 12.2009
- Analyse statistical data and product specifications to determine standards and establish quality and reliability objectives of finished product
- Develop manufacturing methods, labour utilization standards, and cost analysis systems to promote efficient staff and facility utilization
- Recommend methods for improving utilization of personnel, material, and utilities
- Plan and establish sequence of operations to fabricate and assemble parts or products and to promote efficient utilization
- Apply statistical methods and perform mathematical calculations to determine manufacturing processes, staff requirements, and production standards
- Coordinate quality control objectives and activities to resolve production problems, maximize product reliability, and minimize cost
- Confer with vendors, staff, and management personnel regarding procedures, product specifications, manufacturing capabilities, and project status
- Streamline the operations so as to visualise 7 kinds of waste and eliminate them with appropriate method
- Draft the layout of equipment, materials, and workspace to illustrate maximum efficiency using computer
- Review production schedules, engineering specifications, orders, and related information to obtain knowledge of manufacturing methods, procedures, and activities
- Communicate with management and user personnel to develop production and design standards.
Work Study Officer
Dunlop Tyres
Ladysmith
06.2002 - 06.2004
- Time study, Method studies using ILO
- Analyse outputs and report on efficiency
- Follow up on low efficiency
- Training of union members on IE techniques
- Material handling equipment monitoring
- Activity sampling
- Production studies
- Compiling standard time and contingency allowances in terms of ILO
- Report writing
- Was involved in the implementation of Kanban
- Line balancing and cost saving projects
- Capacity planning and manning control
- KMH reports
- Quality auditing on weekly basis
- Industrial Engineering Administrator
- Bonus and Incentive calculation
- Time study and Install time standard in system
- Report to manager
- Quality auditing weekly
- Handling Industrial engineer duties while away
- Awarded the study bursary based on my work performance and my matric results to pursue a career in Industrial engineering.
Production Operator
Masonite Africa Limited
- SPC filing and checks
- Solved and fixed any production problems with the help of Fitter and Foreman
- Giving an award to do ICDL within the company, which was like a competition of who completed it first and was the first to receive the certificate with full modules
- Contactable References
- Company
- Contact Person, Keserin Naicker
- CI Manager 083 250 7076
- Prestige Manufacturing
Group Industrial Engineer
Prestige Apparel Group
Ladysmith
01.2010 - 03.2012
Site Manufacturing Excellence Manager
Nestle SA, Better Opportunities & Growth
ESTCOURT, Kzn
05.2021 - 12.2022
- Qualified
- JIT Best Practice from Theory to practice
- Value Stream Mapping
- Single Minute Die Exchange (SMED)
- Benchmarking on Lean Tools with other companies
- CJ Network Costing Method
- In house Health and Safety course (ISO 1400)
- Achievements
- Saved company a lot of delays and breakdown costs by coming up with decision of implement a Light System for easy tracking at Dunlop Tyres
- Studied the machine with 3 crew operators using activity analysis first and then full production study on each, thus saw the necessity for 2 and saved cost by reducing of one labour at Prestige Group
- Saved the company above 50% by reducing Set-up times of 3 weeks to 3 days by revealing the most problematic areas within the whole process with the help of team leader using Six Sigma approach and SMED at Dunlop Tyres
- Applied Lean manufacturing techniques to utilize the labour in the company, by applying JIT techniques and applied kanban
- Thus, saved one labour, and implemented proper material handling equipment
- Continuously improve the process and saved R 1.5 m a year using Kaizen
- Saved Masonite Africa R10m by executing costs saving projects: Reducing Plate change, improve overall efficiency in Fab, Implementing Long run, Saving on Paint, Eliminated Adhesion problems
- Achieved maturity score of 2.64 in Operational Excellence practices in a period of 4 months at Distell Limited
- Improved Line 01 OEE from 40% to 55% in a period of 8 weeks at Distell Limited by introducing Gemba Walks, Effective Problem Solving and holding relevant people accountable in eliminating Downtimes and Short stops
- Achievements at ABinBev/SAB
- Implemented Voyager Plant Optimisation (VPO) program in Polokwane plant
- The baseline was 13% for all Pillars
- Currently the Plant is sitting at 42%, (as of April 2017), with the yearly target of 50%
- Improvement in the main plant KPI which is Total Extract Loss
- From 8.9% reduced to 6.14% using VPO tools (SDCA problem solving tool) by coaching Brewing manager and her Team leaders on how to solve systematically problems
- Reduced Palletiser Downtime by 50% by using ATO Maintenance pillar together with 5S
- Improvement in Training Bucket plan (VPO) from 80% to 98%, by developing the tracker and publishing results weekly
- Implemented Idea generating system, thus got more engagement from lower levels which shows ownership of problems from shop floor levels
- Managing a budget of R2m allocated to implement (WCM) VPO principles
- The budget is for VPO equipment’s, including training of workers
- Developed site Steercom Implementation Plan for the program
- Monthly consolidating all KPIs figures to the ZONE, Strategic plan development and management in the Factory :- Ensures the right cascading of priorities and measures from the Market to the factory ;- Defines and embeds NCE projects and initiatives into the Factory objectives and align Factory Leadership Team towards the plan - Establishes Factory governance to ensure that NCE implementation contributes to deliver business results;- Drive effective factory governance (simple) - Prioritize the improvement efforts based on loss analysis - Owns as drives the factory capacity plan for the next 5 years with the best cost and service level
- Improvement in overall competence, Leading to empowered and autonomous and engaged people.- Facilitates the FLT to support the factory to achieve their business goals by applying NCE Methodologies;- Facilitates to translate the Market priorities and function priorities into the Factory OMP; - Supports Factory competency building plan that ensures NCE is developing autonomy at all levels of the organization; - Stewards , trains, supports and coaches the Factory Leadership Team and Local Leadership Teams in Manufacturing competencies (e.g.GA, FI, LVS, AM) and applicable manufacturing standards ;- Develops competency of Local Leadership Teams and Factory Leadership Teams, supporting them to apply methodologies to improve and sustain results (e.g
- All NCE methodologies, Value Added Activities, Workload studies, etc.); - Supports the sustained competencies in Manufacturing Excellence for the factory
- Improvement in Manufacturing Excellence results.- Promotes and supports cross-fertilization of Manufacturing best practices, knowledge, standards and improvements across the factories ;- Ensures an overall understanding of the different NCE methodologies (pillars) within the Factory Leadership Team, functions and how they integrate through the NCE implementation plan avoiding silo working;- Conducts specific projects to support results improvement around priorities established by the Factory;- Provides hands-on support to the Local Leadership Teams and Local Operating Teams to accelerate improvement of results (coach by doing with the factory);- Ensures effectiveness of NCE implementation (business results);- Drives pragmatic application of methodologies and tools focusing on delivering results - Understands and ensures together with Factory Cost controller an overall competence of Costing Standards for Manufacturing .- Links with Market Excellence manager within a Market/Category to drive NCE in manufacturing
- Proved successful working within tight deadlines and a fast-paced environment.
- Organized and detail-oriented with a strong work ethic.
- Developed strong communication and organizational skills through working on group projects.
- Completed paperwork, recognizing discrepancies and promptly addressing for resolution.
- Developed and maintained courteous and effective working relationships.
- Exercised leadership capabilities by successfully motivating and inspiring others.
- Gained strong leadership skills by managing projects from start to finish.
- Participated in team projects, demonstrating an ability to work collaboratively and effectively.
- Gained extensive knowledge in data entry, analysis and reporting.
- Cultivated interpersonal skills by building positive relationships with others.
- Demonstrated a high level of initiative and creativity while tackling difficult tasks.
- Worked well in a team setting, providing support and guidance.
- Strengthened communication skills through regular interactions with others.
- Managed time efficiently in order to complete all tasks within deadlines.
- Used strong analytical and problem-solving skills to develop effective solutions for challenging situations.
- Adaptable and proficient in learning new concepts quickly and efficiently.
- Resolved problems, improved operations and provided exceptional service.
- Proven ability to develop and implement creative solutions to complex problems.
- Demonstrated respect, friendliness and willingness to help wherever needed.
- Demonstrated creativity and resourcefulness through the development of innovative solutions.
Site Supply Chain Excellence Manager
Distell Springs, Better Opportunities
09.2018 - 04.2021
- Work hand-in-hand with the General Manager to improve Site major KPIs, namely ME, OEE, Water usages and various costs by utilising Operation Excellence methodologies such as Lean Six Sigma
- Chair Site Steercom meetings and Implementation Task Force
- Coaching and developing High Performance Coachers from the shop floor to management level
- Monthly Supply chain Report to the Centre of Excellence
- Manage supply chain Excellence budget, and allocate resources to execute practices and achieve plant’s KPIs
- Responsible for Cost Savings Projects using Six Sigma
- Managing Supply chain budget
- Site Change Agent
- Facilitates situational and strategic problem-solving coaching to leadership
- Manage site water and electricity usage projects
- Achieved the ‘Most Improved Plant' award in 2019 in Practices and improvement in OEE
- Overall accountability of Asset care and autonomous maintenance practices
- Developed AC and Benchmarking Strategy for Site
- High performance coaching at all levels in the plant
- Responsible for directing management's KPIs and Goal Setting
- Direct the plant charter
- Define the world class standards and practices for the site
- Achieved the maturity score of 2.5 in model areas and rolled out practices across site.
Plant VPO Manager
SAB Miller / ABinbev
05.2017 - 08.2018
- New Opportunities & Relocated due to Family
- Responsibilities:
- To oversee the Manufacturing Development Department, and to be the right-hand person to the Plant manager
- To roll out VPO program at the Plant
- To ensure that the plant Strategic Goal and Dream to be number One in Africa is achieved through execution of VPO Tools across the plant
- Manage the MDEV department
- Develop Steercom implementation plan and ensuring the progress of the plan and Present on master plan progress
- Consolidate the plant progress on VPO world class tools
- Execute VPO Tools across the Plant, by Training, coaching and proving support to all Levels in the plant
- Ensuring that meetings are effective, drive the other pillar champions to close gaps and achieve the score
- Support other pillars (FI, 5s, PMC, Safety, Quality, People, Environmental) in terms of VPO
- Achieve VPO Pillar monthly targets by scoring and coming up with actions to improve and close the gaps.
Continuous Improvement Specialist
Masonite Africa Limited, Seeking
01.2013 - 03.2017
- New challenge
- Responsibilities:
- Facilitate and entrench a Continuous Improvement Culture at the site
- Identify CI opportunities
- Initiate and facilitate Brainstorming sessions
- Identify appropriate KPI improvement opportunities
- Ensure alignment between divisions
- Utilise appropriate tools to drive improvements (VSM, Lean, Six Sigma)
- Participate in Plant KPI meetings
- Monitor and report on KPI performance against target
- Investigate special projects
- Conduct training of plant personnel in appropriate systems and techniques
- Identify resource needs within team
- Develop staff on 6 Sigma
- Coach and mentor staff on their projects
- Communicate effectively with entire team and ensure they are kept informed of company developments
Industrial Engineer
Prestige Manufacturing Industries
Ladysmith
01.2010 - 11.2012
- Retrenched (factory relocated to Lesotho), Implement Best Practice in a non-Lean practicing industry
- Develop manufacturing methods, labour utilization standards, and cost analysis systems to promote efficient staff and facility utilization
- Lead morning meetings and suggest improvements
- Calculate efficiencies and capacity for the factory
- Initiated Lean projects, like to improving the efficiency of the Ironers
- Training of Managers and Shop stewards in Lean skills
- Implementing Lean Tools in the company like Visual Management
- Reducing Set-up times
- Continuous improvements
- JIT systems to eliminate waste of waiting
- Liaising with Top management regarding improvements
- Perform Work study, method study and Activity Sampling
- Implemented Occupational Health Policy
- Implemented Security Policy
- Weekly Safety meetings and Audits
- Major Projects:
- A layout for the company department, outlining 50% savings in terms of Labour, 50% in terms of production loss and waste and 80% in terms of flow and better working methods
- In this area there was no flow of material, thus needs to be re layout to streamline the whole process
- Reducing the mould change of 16 hours applying SMED
- The project involves team members from different expertise
- The target is to half this in three weeks, and half again after 2 weeks till it is single minute change over
- Currently, the changeover is 17 minutes from 16 hours
- Implementing the bladder cage Visual Board with the use of Kanban to reduce waste
- Studied the Area and Implemented proper measurement systems thus increased productivity from 30% to 75 % in a week at Prestige Industries
Project Manager
MANCOSA
05.2012 - 11.2012
- Lean Manufacturing failures and success
- Lean Adoption and lean as a ‘Management Philosophy’
- Lean as a World Class tool and lean Culture
Area Industrial Engineer | Work Study Officer, Industrial Engineering Administrator | Production Operator
Dunlop Tyres
01.2000 - 01.2009
Education
Master of Business Administration (MBA) - Business Administration
College of Southern Africa
Durban 01.2010 - 04.2012
Masters - Industrial Engineering
Tshwane University of Technology
National Diploma - Industrial Engineering
University of South Africa
01.2016 - undefined
BTech - Industrial Engineering
Megamesters College
Project Management and MS - undefined
Certificate in Project Management and MS - undefined
AmaHlubi High School
Senior Certificate - undefined
ICDL Certificate Certificate in Lean Manufacturing and Implementation (Kaizen) Health and Safety Lean Six Sigma GREEN BELT Various training courses, including ISO 9001, Report writing, Rubber Technology and BOP. Industrial Relations - undefined
Skills
Microsoft Office - Word, Excel, PowerPoint, Access, Project, Outlook and Internetundefined
Certification
Lean Six Sigma Green Belt
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Quote
The problem is not to find the answer; it’s to face the answer.
Terence McKenna
Timeline
Site Manufacturing Excellence Manager
Nestle SA, Better Opportunities & Growth
05.2021 - 12.2022
Site Supply Chain Excellence Manager
Distell Springs, Better Opportunities
09.2018 - 04.2021
Plant VPO Manager
SAB Miller / ABinbev
05.2017 - 08.2018
National Diploma - Industrial Engineering
University of South Africa
01.2016 - undefined
Lean Six Sigma Green Belt
06-2014
Continuous Improvement Specialist
Masonite Africa Limited, Seeking
01.2013 - 03.2017
Project Manager
MANCOSA
05.2012 - 11.2012
Master of Business Administration (MBA) - Business Administration
College of Southern Africa
01.2010 - 04.2012
Group Industrial Engineer
Prestige Apparel Group
01.2010 - 03.2012
Industrial Engineer
Prestige Manufacturing Industries
01.2010 - 11.2012
Area Industrial Engineer
Dunlop Tyres
07.2004 - 12.2009
Computer Literate /
06-2002
Work Study Officer
Dunlop Tyres
06.2002 - 06.2004
Area Industrial Engineer | Work Study Officer, Industrial Engineering Administrator | Production Operator
Dunlop Tyres
01.2000 - 01.2009
Masters - Industrial Engineering
Tshwane University of Technology
BTech - Industrial Engineering
Megamesters College
Project Management and MS - undefined
Certificate in Project Management and MS - undefined
AmaHlubi High School
Senior Certificate - undefined
ICDL Certificate Certificate in Lean Manufacturing and Implementation (Kaizen) Health and Safety Lean Six Sigma GREEN BELT Various training courses, including ISO 9001, Report writing, Rubber Technology and BOP. Industrial Relations - undefined
Production Operator
Masonite Africa Limited
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