Gerald Mubatapasango
Experienced Manufacturing and Engineering Professional - Lean Six Sigma Black Belt
East London
Summary
Accomplished engineer with over experience spanning over 15 years. Proficient in Lean manufacturing, Six Sigma, and continuous improvement methodologies. Areas of experience include strategic planning, quality management, continuous improvement, decision making, health and safety and efficiency and effectiveness focus. I am assertive; proactive; a visionary thinker; always challenging the status core; inspirational leader; skilled in creating robust strategies through a collaborative approach in work to translate vision into achievements; exceptional communicator and negotiator; at ease in leading and developing teams; aligning and matching team goals to overall organizational objectives and I have good business acumen. I am a qualified engineer and project/programme manager. I am flexible and can easily adapt to any environment with cross cultural dynamics.
Experienced with delivering strategic consulting services to enhance client business operations. Utilizes in-depth industry knowledge and analytical skills to identify and implement effective solutions. Track record of building strong client relationships and driving measurable results.
Overview
20
20
years of professional experience
12
12
Certifications
Work History
Operational Efficiency Improvement Consultant
Weidplas South Africa East London Plant
09.2024 - Current
- Improving plant quality and productivity performance.
- Process Automation.
- Injection molding process optimization.
- Using Lean Manufacturing and Six Sigma concepts to eliminate waste and recommend process and business improvements.
- Identifying new technologies to enhance efficiency.
- Optimizing production and quality processes.
- Logistics and supply chain process design and improvement.
- Maintenance planning and management.
- IATF Audit findings close-out support.
- Customer complaints investigation using 8D Methodology.
- Process Mapping for new and old processes.
- Process Layout design and optimization.
- Developed and implemented best practices for operational procedures, improving productivity and ensuring consistent quality standards.
- Conducted comprehensive analyses of operational processes to identify inefficiencies, facilitating targeted improvements and cost savings.
- Supported the implementation of new technologies that automated workflows, resulting in significant time savings and accuracy enhancements.
Director
Sieben Management Consultants
03.2024 - Current
- Project Management.
- Manufacturing operations improvements.
- Lean Six Sigma projects.
- Process control, improvement and automation
Operational Efficiency Improvement Consultant
Weidplas South Africa Port Elizabeth Plant
02.2024 - Current
- Improving plant Overall Equipment Effectiveness.
- Productivity improvement.
- Using Lean Manufacturing and Six Sigma concepts to eliminate waste and recommend process and business improvements.
- Identifying new technologies to enhance efficiency.
- Optimizing production and quality processes.
- Working closely with management to develop strategic plans to improve overall organizational performance.
- Logistics and supply chain process design and improvement.
- Maintenance planning and management.
Executive Director
Ignition Impact
03.2017 - 04.2022
- I sourced capital for businesses with viable construction, mining and renewable energy projects.
- I evaluated and added my input to projects to improve proposals and increase delivery efficiency.
- I developed a funding model for the construction industry to help reduce project start-up cost, involved SMMEs in large construction projects as well as improve operational efficiency of the construction value chain.
- Spearheaded strategic initiatives that enhanced organizational efficiency, resulting in significant improvement in project delivery timelines.
- Developed and implemented comprehensive operational frameworks, leading to streamlined processes and improved stakeholder engagement.
Senior Process Engineer
Nissan Motor Corp
08.2012 - 02.2017
- List of departments I worked in; Stamping Plant, Body in White Line and Trim and Chassis Assembly line.
- Led and implemented process improvements for the Front Bumper Fitment concerns resulting in; reduction in downtime on the trim and chassis line, improved chassis quality from the Stamping plant, improved parts quality from suppliers for the D22 front end components as well as improved overall plant operational efficiency.
- Conducted time studies and process mapping to streamline operations and reduce waste.
- Collaborated with design, production, and quality control teams to ensure smooth and cost-effective production processes.
- Designed and improved production layouts and workspaces to optimize material flow and ergonomics.
- Developed and implemented preventive maintenance programs to minimize equipment downtime.
- Analyzed production data and KPIs to identify inefficiencies and implement corrective actions.
- Conducted root cause analysis on quality issues and implemented corrective actions, reducing defect rates.
- Developed and implemented process optimization strategies, resulting in increased operational efficiency across multiple manufacturing lines.
- Led cross-functional teams to enhance quality control measures, significantly reducing defect rates and improving product reliability.
- Spearheaded the integration of advanced manufacturing technologies, streamlining production workflows and minimizing downtime across facilities.
Process Engineer
Takata Petri SA
05.2008 - 07.2012
- List of departments I worked in; Aluminum and Magnesium Die Casting, Injection Molding Line, Leather Covering Line.
- Spearheaded the introduction of new technology on the injection molding production line, (Gas loading tanks and automation controls), resulting in a 40% reduction in steering wheel reworks and overall plant performance.
- Managed the installation and testing of manufacturing equipment to ensure it met operational requirements.
- Implemented Lean and Six Sigma initiatives that led to a reduction in waste by 20%.
- Trained production staff on new equipment and manufacturing processes to ensure compliance with safety and quality standards.
- Collaborated with customer to ensure timely procurement of materials and parts.
- Led process optimization initiatives to enhance production efficiency, resulting in reduced cycle times and improved output quality.
- Developed and implemented standard operating procedures to streamline manufacturing processes, contributing to increased compliance with industry standards.
- Collaborated with cross-functional teams to identify and resolve production bottlenecks, resulting in enhanced workflow and reduced downtime.
Production Planner
Seipone Exhibits t/a Kubik
10.2007 - 12.2007
- I played a key role in developing and optimizing manufacturing processes to ensure high quality and productivity.
- I collaborated with cross-functional teams to design and implement process improvements, troubleshoot process issues, and propose effective solutions.
- Introduced a Just in Time system for materials and consumable orders to reduce inventory.
- Collaborated with construction site teams to ensure timely delivery of the components.
Production Engineer
Deven Engineering
07.2005 - 03.2006
- Optimizing manufacturing processes to improve efficiency
- Quality Management
- Production planning and scheduling
- Maintenance management
Education
Master of Commerce Degree - Program Management
Cranefield College
South Africa03.2016
Bachelor of Technology Honors Degree - Production Engineering
Chinhoyi University of Technology
Zimbabwe07.2007
Skills
Certification
Nissan V-Fast facilitator (Six Sigma Green Belt) – Nissan Motor Corp, 2015.
Timeline
Operational Efficiency Improvement Consultant
Weidplas South Africa East London Plant
09.2024 - Current
Director
Sieben Management Consultants
03.2024 - Current
Operational Efficiency Improvement Consultant
Weidplas South Africa Port Elizabeth Plant
02.2024 - Current
Executive Director
Ignition Impact
03.2017 - 04.2022
Senior Process Engineer
Nissan Motor Corp
08.2012 - 02.2017
Process Engineer
Takata Petri SA
05.2008 - 07.2012
Production Planner
Seipone Exhibits t/a Kubik
10.2007 - 12.2007
Production Engineer
Deven Engineering
07.2005 - 03.2006
Master of Commerce Degree - Program Management
Cranefield College
Bachelor of Technology Honors Degree - Production Engineering
Chinhoyi University of Technology