Johan Kleynhans

Professional Experience

Operations Manager (DMRE 3.1 Appointee)
Dikwena Chrome (Brits) – Mar 2022 to Feb 2023
Tubatse Alloy Smelter (Driekop) – Mar 2023 to Present

• Leadership and Team Management: Lead production and maintenance teams for the Dikwena Chrome D3 and D4 ferrochrome furnaces and the Tubatse Alloy Smelter A3 furnaces, overseeing approximately 100 personnel at each plant.
• Operational Excellence: Developed and implemented operational procedures to ensure adherence to quality standards and enhance overall process efficiency.
• Continuous Improvement: Monitored and optimized production processes, improving team performance and customer service. Continuously identified and implemented improvements in methods, equipment, and processes to exceed production targets and reduce costs.
• Strategic Planning: Documented and reviewed the overall production and maintenance strategy annually, aligning it with the business unit's strategic plan.
• Risk Management: Identified and assessed issue-based risks, considering business, financial, legal, and environmental exposures.
• Maintenance Management: Ensured adherence to maintenance management principles to achieve maximum plant availability at minimal maintenance costs.
• Human Resources: Managed department HR functions, including performance management, disciplinary actions, labor relations, and maintaining a positive organizational climate.
• Performance Measurement: Developed key performance indicators (KPIs) to measure the effectiveness of operational processes.
• Data Analysis: Analyzed data from daily reports to identify trends in production performance metrics, driving informed decision-making and process improvements.

Consultation Work

• Community Development Project – Citrus Farm, Steelpoort Valley:
  Leading a community development project to establish a citrus farm in collaboration with the local community, large-scale citrus farmers, and mining companies. The project follows a Design, Build, Operate, Train, and Transfer (DBOTT) model. The goal is to transfer the business to the community after equipping them with the necessary skills and knowledge.
• Collaboration Forum:
  Leading the establishment of a proposed collaboration forum involving government, industry stakeholders, citrus farms, and the community. The forum aims to streamline communication, address issues and concerns, and identify development opportunities.

Schuitema Group
Schuitema Group is a consultancy dedicated to the enhancement of human excellence. Offering leadership training and management consulting, the company aims to transform organizational culture by enabling individuals to lead through powerful values that expand brand excellence. Schuitema Group’s mission is to inspire leaders, teams, and individuals to realize their full potential and transform their environments. Working hand in hand with organizations, Schuitema Group fosters strong, productive, and respectful cultures.

Plant Management

• Comprehensive Oversight: Managed the entire plant, which includes six submerged arc ferrochrome producing furnaces, a chrome recovery plant, a power generation plant, a water treatment plant, and a pelletizing and sintering plant.
• Team Leadership: Oversaw 625 full-time employees and over 200 permanent contractors. Direct reports included the HR Manager, Finance and Admin Manager, Logistics Manager, three Operations Managers, Engineering Manager, and SHEQ (Safety, Health, Environment, and Quality) Manager.

Key Responsibilities:

• Operational Strategies: Developed and implemented strategies to enhance efficiency, reduce costs, and maximize customer satisfaction.
• Production Management: Managed production volume and site cost of production against set budget targets. Conducted yearly production forecasting, budgeting, and strategic planning.
• SHEQ Standards: Maintained group-wide SHEQ standards and ensured adherence to audits. Managed environmental issues effectively.
• Communication: Established and maintained effective communication with staff members to ensure smooth and efficient operations.
• Training and Development: Ensured comprehensive training and development programs across the site. Measured subordinates' performance through individual development plans and performance contracts.
• Performance Management: Monitored daily production metrics, including efficiency drivers, availability, utilization, recovery, and specific energy consumption, fostering a culture of continuous improvement.
• Project Management: Led technical and capital projects to support plant operations and improvements.

Achievements:

• Cost Reduction: Achieved a significant reduction in the total cost of production each year from 2017 to 2020 by implementing an in-house built Cost of Production (COP) model. This model facilitated business decision-making and forecasting, identifying and monitoring cost reduction plans effectively.

Operations Manager: West Plant Furnaces
Jul 2011 – Jun 2013

• Led production and maintenance functions for the West Plant furnaces, overseeing a team of 100 employees.

Operations Manager: West Plant and PSP
Jun 2013 – Jun 2014

• Managed operations of two ferrochrome producing furnaces at the West Plant and the Pelletizing and Sintering Plant (PSP2), supervising a total of 160 employees.

Operations Manager: Tubatse Furnaces (East and West Plants)
Jun 2014 – Sep 2016

• Managed operations for all six ferrochrome producing furnaces at Tubatse Chrome (T1 to T4 at East Plant and T5 and T6 at West Plant), leading a team of 260 employees, including six superintendents.

Achievements:

• Increased Furnace Utilization: Achieved a significant increase in furnace utilization from 2008 to 2015.
• Reduced Electrode Paste Consumption: Significantly reduced electrode paste consumption at the Tubatse West Plant furnaces (T5 & T6).
• Cost Reduction: Successfully reduced furnace cost of production by increasing and sustaining the use of low-value ore at the Tubatse West Plant furnaces (T5 & T6) from 2008 to 2012.
• Skimmer Block Tapping Implementation: Implemented Skimmer Block tapping at Tubatse Ferrochrome's West Plant, making T5 the first furnace to use this technique, completed in 2012, followed by T6 in the same year.
• Furnace Rebuild Projects: Contributed to the completion of numerous furnace rebuild projects at Tubatse Chrome.
• Cr Recovery Improvement: Enhanced Cr recovery through metallurgical changes, earning a "Chrome Award" in May 2011 for the contribution.
• Slag Basicity Reduction: Improved Cr recovery by reducing slag basicity at the Tubatse Chrome furnaces in 2014.
• Electrode Management: Enhanced electrode management and practices at Tubatse Ferrochrome.

• Team Leadership: Led the West Plant production team of approximately 60 people, overseeing all production processes.
• Operational Monitoring: Monitored daily production operations to ensure compliance with established policies and procedures.
• Efficiency Strategies: Developed and implemented strategies to improve operational efficiency and effectiveness.
• Technical Guidance: Provided technical expertise to resolve process-related issues and enhance production outcomes.
• Process Improvement: Analyzed product specifications to identify and implement appropriate process improvements.
• Production Planning: Directed the development and execution of production plans, schedules, and objectives to meet organizational goals.

• Production Management: Assisted in managing production volume and furnace cost of production for the West Plant furnaces.
• Safety Oversight: Managed safety systems and monitored safety statistics for both production shift and day shift personnel.
• Root Cause Analysis: Participated in Root Cause Failure Analysis (RCFA) sessions and investigations to identify and address operational issues.
• Technical Operations: Oversaw the technical operations of furnaces T5 and T6, ensuring optimal performance and efficiency.

• Technical Projects and Production: Managed technical projects and production work at the Modikwa Concentrator.
• Metallurgical Laboratory Head: Led the Metallurgical Laboratory, overseeing two graduate metallurgists.
• Process Evaluation: Conducted routine metallurgical work and process evaluations, managing plant-specific projects.
• Process Monitoring: Monitored and adjusted hydrometallurgical production processes to ensure optimal production volumes and product quality.

Modikwa Platinum Concentrator
Anglo Platinum and ARM joint venture

• Beneficiated PGM-bearing ores through milling and froth flotation before smelting.
• Analyzed metallurgical test data to identify trends in plant performance.

• Monitored production efficiency and quality, identifying issues and recommending corrective actions.
• Adjusted production parameters to ensure product quality.
• Developed project plans, budgets, and timelines for successful project completion.
• Managed resources, including equipment, materials, personnel, and subcontractors, to achieve project goals.

The Precious Metals Refiners (PMR)
PMR handles the final processing step in Platinum Group Metals production.

• Process Engineer, Project Engineering Department:Managed plant modifications and projects, including design, testing, and commissioning.
  Solved complex problems and led HAZOP study meetings.