Summary
Overview
Work History
Education
Accomplishments
Manufacturing Systems
References
Timeline
Generic

Ian Marsh

Summary

Dynamic Manufacturing Plant Manager with extensive experience leading large-scale tire operations in global automotive supply companies, demonstrating a strong track record of success in complex manufacturing environments. Expertise includes engineering, quality assurance, R&D, production management, and Six Sigma methodologies, supported by a solid foundation in continuous improvement and process optimization. Proven ability to manage significant CAPEX projects while fostering a culture of collaboration and excellence among diverse teams. Committed to delivering world-class results through strategic implementation of organizational change and enhancement of teamwork across multiple disciplines.

Overview

43
43
years of professional experience

Work History

Consultant

TCS Tire Services
04.2020 - Current
  • Evaluated client needs and expectations, establishing clear goals for each consulting engagement.
  • Streamlined internal processes to enhance team efficiency and improve overall project outcomes.
  • Managed client relationships through regular check-ins and updates on project progress.
  • Enhanced communication among team members to foster collaborative and supportive work environment.

Manufacturing - Factory Modernization Manager

Bridgestone Tyres South Africa
09.2018 - 03.2020
  • Plant modernization – all facilities
  • Design and prepare factory floor for new installations
  • Installation of new equipment to meet future OE requirements - Rolling resistance, noise, wet skid
  • Responsible for Capital expenditure
  • Lead project team

Executive Manager Manufacturing - Plant Director

Bridgestone Tyres South Africa
05.2016 - 09.2018
  • Implement a manufacturing turnaround strategy to support total business turnaround by maximizing plant output
  • Driving a safety/environmental culture in the factories
  • Ensure budgeted levels are met in factory costs with the main focus on conversion costs and excessive waste levels
  • Implementation of ‘Quality First' mentality
  • Provide leadership and direction to the factory operating teams
  • Introduce S&OP process
  • Develop KPI's in line with corporate strategy
  • Restructure manufacturing organization to ensure efficient delivery of Business Plan objectives
  • Implement quality systems to ensure product that meets customer expectation
  • Ensure compliance to ISO/TS/IATF Standards
  • Ensure factory investment is in line with future technology and market growth both in OE and replacement markets
  • Deliver daily/monthly results-Safety, Quality, Waste, Productivity, Cost, People, Innovation
  • Implement and drive Continuous Improvement/Lean manufacturing processes
  • Implementation of Integrated Work Systems – reorganize plant organizational structure accordingly
  • Change management behavior from autocratic top down to a servant leadership bottom up type style
  • Prepare plant for successful conversion from TS to IATF 16949

Plant Manager

Goodyear Tyres South Africa
01.2010 - 12.2014
  • Responsible for plant and relevant ISO/TS requirements
  • Provide leadership to the factory operations team
  • Developing BP in line with company targets
  • Setting and achieving plant KPI's
  • Driving a safety/environmental culture in the plant – internal and external
  • Development of staff
  • Deliver daily results- Quality, waste, quantity, cost
  • Drive Continuous Improvement/Lean manufacturing processes

Quality and Technology Manager

Goodyear Tyres South Africa
01.2007 - 12.2010
  • Ensuring all procedures and specifications are in place and adhered to throughout factory
  • Ensuring all outgoing product meets correct specification
  • Development and introduction of new products in line with OE or market requirements – pre-production processes and signing new product and processes off to production
  • Customer satisfaction
  • Drive uniformity and waste programs

Business Unit Manager and 6 Sigma Black Belt

Goodyear Tyres South Africa
01.2004 - 12.2007
  • 5S, Kanban, Supermarket, Kaizen, DMAIC etc.

Technology Team Leader

Goodyear Tyres South Africa
01.2003 - 12.2005

Process Engineer

Goodyear Tyres South Africa
01.1989 - 12.2003
  • New product designer
  • Cure compounder - Thermocouples
  • PPAP
  • Uniformity specialist
  • Waste control specialist

Robotics Programmer

Volkswagen South Africa
01.1983 - 12.1989
  • Electrical technician
  • Electrician

Education

Chemistry – Rubber and Plastics diploma -

PE Technicon

Quality – Statistics diploma - undefined

City and Guilds of London

6 Sigma – Black belt - yellow belt, green belt, advocacy

Business management diploma - undefined

Cape Town School of business

Advanced business management - undefined

Mahler USA

N5 - Electrical engineering - Partial N6 - stopped due to career change

Electrical artisan/ technician - undefined

VWSA

Accomplishments

  • Goodyear, Received global achiever award (1st out of 88000 employees globally) for mastering the quality turnaround in the factory.
  • Bridgestone, Improved morale and results of the manufacturing organization through implementation of continuous improvement processes (IWS - Integrated Work Systems), frequent relevant communication, changing management style from top down autocratic to servant leadership bottom up and addressing many long term problematic concerns from the shop floor.
  • Bridgestone, Successful implementation (on time and in budget) of Capital projects of >R500M.
  • Bridgestone, Part of turn around executive team that returned the business to profitability.
  • Bridgestone, >1.6 million injury free hours.
  • Bridgestone, Study the requirement for plant modernization project to satisfy OE customer needs to move to environmentally friendly products (emissions and noise).
  • Bridgestone/Goodyear, Design automated final inspection area to world class standards.
  • Goodyear, Reduced vibration of tyres through 6 sigma Black Belt process.
  • Bridgestone/Goodyear, Re-establishing quality systems and procedures to pass regional quality audit qualifying the plant to export product into sensitive markets.
  • Goodyear, Consistently rated in the top performance category in annual performance review and part of fast track program for high potential performers – numerous overseas assignments.
  • Bridgestone, Implement new shift pattern (move away from non-productive 12 hour to 8 hour with overlap for improved continuous operations).
  • Goodyear, First non-executive to be sent on the Executive Development program – Mahler institute USA.

Manufacturing Systems

  • Knowledge of employment legislations (LRA, EEA)
  • Knowledge of factory regulations act
  • Experience in ISO 9000, 14000 and 18000 systems
  • Experience in OHS Act
  • Experience TS16949 OE Standard
  • Experience in IATF16949 OE Standard
  • SAP
  • Microsoft Excel, Word, PowerPoint
  • Problem solving techniques – 6 Sigma, 8D, 5Y, TQM, 4M etc.
  • Manufacturing Execution Systems
  • S&OP Process
  • Minitab (Statistical tool)
  • Business Plan Development

References

  • Marius Fourie, Human Resources Manager, Goodyear SA, +27 827848224
  • Naas Terblanche - Owner TCS Tire Services, +27824599638

Timeline

Consultant

TCS Tire Services
04.2020 - Current

Manufacturing - Factory Modernization Manager

Bridgestone Tyres South Africa
09.2018 - 03.2020

Executive Manager Manufacturing - Plant Director

Bridgestone Tyres South Africa
05.2016 - 09.2018

Plant Manager

Goodyear Tyres South Africa
01.2010 - 12.2014

Quality and Technology Manager

Goodyear Tyres South Africa
01.2007 - 12.2010

Business Unit Manager and 6 Sigma Black Belt

Goodyear Tyres South Africa
01.2004 - 12.2007

Technology Team Leader

Goodyear Tyres South Africa
01.2003 - 12.2005

Process Engineer

Goodyear Tyres South Africa
01.1989 - 12.2003

Robotics Programmer

Volkswagen South Africa
01.1983 - 12.1989

Quality – Statistics diploma - undefined

City and Guilds of London

6 Sigma – Black belt - yellow belt, green belt, advocacy

Business management diploma - undefined

Cape Town School of business

Advanced business management - undefined

Mahler USA

N5 - Electrical engineering - Partial N6 - stopped due to career change

Electrical artisan/ technician - undefined

VWSA

Chemistry – Rubber and Plastics diploma -

PE Technicon
Ian Marsh