Summary
Work History
Education
Skills
Systems Standards And Methodologies
References
Timeline
Generic

KHULEKANI SIBIYA

Engineering & Technical Operations Leader
Isithebe,KwaZulu-Natal

Summary

Engineering & Technical Operations Leader with over 12 years of experience across industrial engineering, manufacturing, process engineering, production engineering, maintenance engineering, utilities management, quality systems, reliability engineering, technical operations, infrastructure projects, and operational leadership. Extensive experience leading multidisciplinary engineering operations involving utilities, boilers, steam systems, coal systems, compressors, electrical systems, grain silos, water treatment plants, workshops, brewing systems, infrastructure restoration, CAPEX projects, operational optimization, food safety systems, process safety, and engineering governance. Strong industrial engineering capability in process optimization, operational efficiency, OEE improvement, process troubleshooting, time and work studies, data analysis, continuous improvement, manufacturing systems, maintenance planning, supplier management, engineering compliance, operational cost reduction, asset reliability, and production support.

Work History

Engineering HOD

Universal National Breweries (Delta Group)
Isithebe, KwaZulu-Natal
  • Lead engineering operations across brewing plant, malting plant, utility systems, grain silo systems, engineering workshop, and infrastructure assets.
  • Manage utilities including boilers, steam systems, coal systems, compressors, electrical infrastructure, water treatment systems, and effluent operations.
  • Lead preventive maintenance, shutdown planning, reliability engineering, operational continuity, and asset restoration strategies.
  • Manage CAPEX and infrastructure projects involving roads, paving, buildings, structural restoration, plant modifications, and engineering upgrades.
  • Lead engineering governance, Permit to Work/Havoc systems, SOP implementation, engineering compliance, and food safety systems.
  • Manage supplier onboarding, contractor performance, engineering audits, technical inspections, and compliance controls.
  • Conduct utility analysis, coal analysis, supplier evaluations, mining supplier interactions, technical investigations, and operational improvement initiatives.
  • Key Measurable Achievements
  • Led silo restoration initiatives projected to eliminate third-party silo dependency, supporting estimated savings exceeding R2 million per month.
  • Improved engineering turnaround and restoration execution efficiency by approximately 35% through enhanced maintenance planning and coordination.
  • Improved Permit to Work/Havoc system utilisation and compliance tracking by over 40%.
  • Improved utility reliability and operational efficiency by approximately 25% through optimization of steam, coal, compressors, water systems, and electrical infrastructure.
  • Reduced coal quality-related operational disruptions by over 30% through coal specification reviews, supplier onboarding, and fuel governance.
  • Improved maintenance planning and engineering coordination efficiency by 45% through development of maintenance planning functions.
  • Led CAPEX and infrastructure projects valued at multiple millions of rands involving roads, paving, structural restoration, and engineering upgrades.
  • Improved engineering compliance readiness and food safety alignment by over 30% through restoration programs and SOP improvements.

Unilever South Africa
  • Improved Overall Equipment Effectiveness (OEE) within the packing hall by 12% through operational optimization initiatives.
  • Reduced breakdown loss time by approximately 30% through preventive maintenance and reliability engineering improvements.
  • Reduced pastry waste within the cube department by 29% through process optimization initiatives.
  • Improved planned maintenance compliance by over 35% through maintenance governance and planning controls.
  • Led FIFO restoration and process flow improvement initiatives improving stock rotation and operational material flow efficiency.
  • Reduced changeover times through SMED and continuous improvement methodologies.
  • Improved supplier quality performance through onboarding of resilient suppliers and engineering quality initiatives.

Education

Advanced Diploma - undefined

Industrial Engineering

Skills

  • Industrial Engineering
  • Process Engineering
  • Production Engineering
  • Manufacturing Engineering
  • Engineering Operations Leadership
  • Utilities & Infrastructure Management
  • CAPEX / OPEX Budget Management
  • Financial & Cost Control
  • Coal Management & Coal Quality Analysis
  • Fuel Specifications & Supplier Compliance
  • Mining Supplier Coordination & Site Exposure
  • Coal Supplier Audits & Evaluations
  • Coal Utilisation & Fuel Efficiency
  • Boilers, Steam & Energy Systems
  • Utility Analysis & Optimization
  • Water Treatment & Effluent Systems
  • Reliability Engineering & Asset Integrity
  • Preventive Maintenance Systems
  • Plant Engineering & Technical Services
  • Maintenance Planning & Shutdowns
  • Food Safety & Process Safety
  • FSSC & Compliance Systems
  • Permit to Work / Havoc Systems
  • Risk Assessments & Audits
  • Supplier Management & Vendor Development
  • Contractor & Stakeholder Management
  • Data Analysis & Engineering Reporting
  • Advanced Excel & KPI Management
  • Time & Work Studies
  • Process Optimization & Continuous Improvement
  • OEE Improvement & Manufacturing Efficiency
  • Root Cause Analysis (RCA)
  • Lean Manufacturing & Waste Reduction
  • SMED & Operational Excellence
  • Engineering Governance & SOP Development
  • Technical Investigations & Troubleshooting
  • Infrastructure Restoration Projects
  • People Management & Team Leadership
  • Operational Cost Reduction
  • Cross-Functional Operations Leadership

Systems Standards And Methodologies

  • SAP HANA
  • Lean Manufacturing
  • TPM
  • SMED
  • Kaizen
  • 5S
  • RCA
  • FMEA
  • Preventive Maintenance
  • Reliability Engineering
  • Permit to Work/Havoc Systems
  • FSSC
  • CAPEX Management
  • Utility Optimization
  • Engineering Governance
  • Maintenance Planning
  • OEE Improvement
  • Operational Excellence
  • Process Optimization
  • Time & Work Studies
  • Coal Specifications
  • Coal Quality Analysis
  • Fuel Governance
  • Mining Supplier Coordination
  • Supplier Quality Audits

References

References available on request

Timeline

Engineering HOD

Universal National Breweries (Delta Group)

Unilever South Africa

Advanced Diploma - undefined

Industrial Engineering
KHULEKANI SIBIYAEngineering & Technical Operations Leader