Ignatius Phiri
Mechanical Engineer (Bachelor Of Mechanical Engineering/Diploma In Mechanical Eng./Certicate In Sugar Engineering)
Blantyre
Summary
Hardworking Engineer bringing 26+ years of experience performing diverse maintenance and Operations duties. Dedicated to maintaining optimal equipment functionality by managing routine and complex equipment and facility matters. Strong knowledge of plant and power generation, operation and statutory safety measures.
Dedicated, Focused Manager and analytical problem-solver with talents for team building, leading and motivating, as well as excellent customer relations aptitude and relationship-building skills. Proficient in using independent decision-making skills and sound judgment to positively impact company success. Dedicated to applying training, monitoring and morale-building abilities to enhance employee engagement and boost performance.
Overview
28
28
years of professional experience
5
5
years of post-secondary education
Work History
Maintenance Manager
Illovo Sugar - Nchalo Estate
Nchalo
09.2020 - Current
- Trained and developed maintenance teams to improve safety, employee relations and resolve issues and achieved improvements in performance, preventive maintenance and safety.
- Spearheaded a process for defect reporting and interruption to flow with root cause analysis and corrective action problem solving
- Managed, evaluated and controlled assigned areas of budget, schedule and quality of work (Frontend, Backend, Boilers & Powerhouse, Packing Station & Warehouse)
- Delivered on time and in-budget maintenance programs (including off-crop abnormal and normal programs).
- Implemented scheduled maintenance, retooling production status sheets (defects elimination books) and driving reliability centred maintenance tasks to achieve scheduling effectiveness.
- Developed subordinate lead direct reports through delegation of duties, coaching, mentoring and execution of plant-wide maintenance programs.
- Developed and implemented employee succession programs to promote top performance.
- Established and documented protocols for preventive maintenance procedures, decreasing equipment issues and reducing downtime.
- Created and implemented maintenance programs to optimize operational efficiency in line with Group Performance expectations.
- Managed Shredder Turbine Major Overhaul with local resources when OEM couldn't come to site due to Covid-19; a 1st in Illovo
- Constructed and got AIA Certified 25 ton capacity Hilo #2 Unloader for Nchalo using local resources- a 1st in Illovo
- Communicated best practices among on-site and external personnel to align efforts and goals of the Illovo Quality Way as 5S champion for the plant.
- Cultivated positive rapport with fellow employees to boost company morale and promote employee retention.
- Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.
- Trained personnel in equipment maintenance and enforced participation in exercises focused on developing key skills.
- Assisted in organizing and overseeing assignments to drive operational excellence.
- Controlled resources and assets for department activities to comply with industry standards and government regulations.
- Reviewed established policies and procedures to take on temporary leadership positions, motivate employees and facilitate smooth factory operations.
- Planned and controlled off-crop activities by anticipating works and developing activity charts to manage and control work within the prescribed financial and timelines inline with budget.
- Conducted interviews for new team members (management level) in liaison with HR business Partner and discipline Engineers.
- Optimized equipment maintenance by ensuring that LTA and OTE data is maintained and analyzed by Engineers and Foremen on a weekly basis to drive down deficiencies and improve plant availability.
- Maintained equipment and work environment safe by conducting regular Inspections of equipment and components including lifting equipment and lifting tackles, gas equipment, turbine over-speeds, boiler drum level tests, and machinery safety guards and devices to mitigate the risk of factory accidents.
Production Support Specialist
Illovo Sugar Malawi PLC, Nchalo Estate
Chikwawa
04.2020 - 09.2020
- Worked closely with Process & Boiler operations, laboratory and packing station and warehousing staff on daily material/chemical requirements; investigated and resolved common issues.
- Provided daily support with escalated issues resolution and liaised with line foremen and technical leads.
- Conferred with internal staff to deliver smooth functioning and minimal downtime of newly implemented systems and procedures in line with Fit For Future program.
- Represented Operations team at Production review meetings
- Maintained organized work area by cleaning and removing hazards.
- Calibrated machines with instrumentation staff to maintain required productivity levels and adherence to quality standards.
- Prepared reports and technical documentation of day-to-day production processes.
- Reviewed production schedules and streamlined processes.
Engineering Manager - Operations
Illovo Sugar Malawi PLC - Nchalo Estate
Chikwawa
01.2014 - 04.2020
- Managed and led the engineering functions of Extraction, Process Plant Maintenance and Packing Station and Warehousing.
- Provided Engineering support through effective throughput planning and control by closely working with the Process Manager and plant Engineers to identify potential areas of improvement (operational, maintenance and quality) and implements approved changes.
- Provided a safe working environment for all employees and contractors by implementing effective SHERQ systems including sectional audits, safety talks and planned task observations.
- Implemented SHERQ standards as per ISL requirements by ensuring that effective corrective and/or preventative action is taken on all identified deviations through Zero major or repeat findings in the section during audits and inspections and Zero "Not started" and "Major Delay" on audit and SHE rep monthly inspection action plans.
- Set up planned maintenance objectives, standards, procedures and schedules on material, human and times resource allocations.
- Devised and reviewed WI for Frontend, Backend, Packing Station and Warehouse to ensure continuous improvement of technical services.
- Developed short term and long term Frontend, Backend, Packing Station and Warehouse objectives to achieve seasonal LTA, TCH, OTE, Sucrose Extraction, (low) bagasse moisture, required imbibition, MJ DAC purity, and packing machine effectiveness and quality.
- Developed and implemented predictive maintenance techniques such as thermography, oil and vibration analysis to proactively prevent equipment failure.
- Coordinated scheduled work and breakdown corrective works by liaising with discipline Engineers, Foremen and the Factory manager and other stakeholders in the cane supply-chain to review the planned work activities and schedules to ensure timeous completion of all work.
- Monitoring the factory performance (condition monitoring) for the determination of areas that require attention to mitigate risks of breakdowns by conducting plant inspection.
- Maintaining Illovo’s technical standards by conducting functional research and development (searching the market for relevant equipment and performance testing them) to obtain the best technological and economical solutions to the business.
Senior Plant Engineer
Illovo Sugar Malawi PLC - Nchalo Estate
Chikwawa
05.2012 - 12.2013
- Designed and enforced best-practice methodologies.
- Served as point of contact during plant emergencies, overseeing disaster recovery and expediting restoration efforts.
- Organized and managed maintenance staff to fulfill requirements via scheduling and delegation.
- Remained abreast of new and emerging industry regulations and guidelines for plant operations.
- Drafted preventive maintenance schedules around avoiding service disruptions and equipment breakdowns.
- Audited and trained maintenance personnel to verify presence of necessary skills and competencies.
- Created standardized set-ups for staff workstations and tools to streamline opening and closing operations.
- Complied with applicable mechanical and electrical regulatory standards for Nchalo Mill operations.
- Maintained open communication channels to verify prescribed operational levels for equipment and tasks.
Plant Engineer - Mechanical
Illovo Sugar Malawi - Nchalo Estate
Chikwawa
03.2009 - 12.2013
- Audited and trained maintenance personnel to verify presence of necessary skills and competencies.
- Complied with applicable mechanical regulatory standards for sugar mill plant operation.
- Drafted preventive maintenance schedules around avoiding service disruptions and equipment breakdowns.
- Designed and enforced best-practice methodologies.
- Prepared performance appraisals of plan personnel, highlighting exceptional performances and illustrating remedial requirements.
- Created standardized set-ups for staff workstations and tools to streamline opening and closing operations.
- Remained abreast of new and emerging industry regulations and guidelines for plant operations.
- Organized and managed maintenance staff to fulfill requirements via scheduling and delegation.
Packaging & Warehouse Manager
Illovo Sugar Malawi
Chikwawa
01.2002 - 03.2009
- Developed SKU level demand forecasts for all raw, refined and special sugars
- Assisted with pre and post demand plan forecasting processes and reporting
- Minimized waste and reduced volume of packaging materials used to prepare shipments.
- Reviewed orders by inspecting labeling, packaging and contents.
- Protected materials for transport by correctly packaging products in boxes and crates.
- Helped implement ISO9001:2000 and ISO 22000
- Managed the Packing station/Warehouse operations and maintenance in line with set business objectives
Production Manager
Unilever South East Africa
Blantyre
03.1998 - 12.2001
- Assessed manufacturing processes and recommended improvements to increase productivity.
- Determined suitable crew requirements, scheduled employees and worked with human resources to meet changing production schedules.
- Wrote and conducted formal performance reviews for production personnel.
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Created and regularly updated department work instructions and reports.
- Managed continuous improvement initiatives to drive gains in quality, flow and output.
- Studied department operations to assist with development of new or improved methods of tooling and production processes.
- Implemented quality improvement changes to minimize product defect rates.
- Reviewed maintenance and repair problems to determine appropriate action for resolution.
- Reviewed work for quality and compliance with company standards and design specifications.
- Managed internal operational standards and productivity targets.
- Applied lean practices to balance workflow and eliminate unnecessary steps.
- Resolved issues quickly to maintain productivity goals.
Management Trainee - Technical
Unilever South East Africa
Blantyre
03.1996 - 03.1998
- Assisted established management staff with operational oversight, business development and process improvement strategies.
- Handled day-to-day operations of Elida Ponds; personal products manufacturing as Production Manager
- Worked as a Projects Engineer for the Soaps plant by installing SWING Saponification Reactors as well as in-situ polymerization of alkaline sodium silicate
- Introduced Total Productive Maintenance for the soaps plant as a project.
Education
Certificate in Sugar Engineering - Sugar Engineering
University of KwaZulu-Natal (SMRI)
Durban, South Africa 08.2012 - 12.2012
Bachelor of Science - Mechanical Engineering
University of Malawi - Polytechnic
Blantyre, Malawi 09.1993 - 09.1995
Diploma in Mechanical Engineering - Mechanical Engineering Technology
University of Malawi - Polytechnic
Blantyre, Malawi 09.1990 - 08.1993
Skills
Manufacturing and Operations Management
undefinedTimeline
Maintenance Manager
Illovo Sugar - Nchalo Estate
09.2020 - Current
Production Support Specialist
Illovo Sugar Malawi PLC, Nchalo Estate
04.2020 - 09.2020
Engineering Manager - Operations
Illovo Sugar Malawi PLC - Nchalo Estate
01.2014 - 04.2020
Certificate in Sugar Engineering - Sugar Engineering
University of KwaZulu-Natal (SMRI)
08.2012 - 12.2012
Senior Plant Engineer
Illovo Sugar Malawi PLC - Nchalo Estate
05.2012 - 12.2013
Plant Engineer - Mechanical
Illovo Sugar Malawi - Nchalo Estate
03.2009 - 12.2013
Packaging & Warehouse Manager
Illovo Sugar Malawi
01.2002 - 03.2009
Production Manager
Unilever South East Africa
03.1998 - 12.2001
Management Trainee - Technical
Unilever South East Africa
03.1996 - 03.1998
Bachelor of Science - Mechanical Engineering
University of Malawi - Polytechnic
09.1993 - 09.1995
Diploma in Mechanical Engineering - Mechanical Engineering Technology
University of Malawi - Polytechnic
09.1990 - 08.1993
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