Sibusiso Mbokazi
Plant Manager
Johannesburg
Summary
Experienced manufacturing professional specializing in plant operations and production management. Known for implementing process improvements that boost operational efficiency and product quality. Collaborative team player focused on achieving results and adapting to changing needs. Bringing valuable organizational and leadership skills to the table. Results-driven management professional with a proven track record in overseeing plant operations and optimizing production processes. Skilled in fostering team collaboration, ensuring operational efficiency, and adapting to evolving demands. Strong background in resource management, process improvement, and safety compliance. Consistently delivering impactful outcomes through strategic leadership and decisive action.
Overview
25
25
years of professional experience
6
6
years of post-secondary education
Work History
Plant Manager
Scott Bader
09.2024 - Current
- Forecasted future production needs accurately, allowing for strategic decision-making regarding staffing levels, equipment investments, and inventory management.
- Reduced costs by eliminating materials waste and unnecessary labor hours.
- Boosted employee morale and productivity through effective leadership and motivational techniques.
- Mentored and developed staff members, promoting professional growth opportunities within the organization.
- Enhanced safety standards with implementation of comprehensive safety training initiatives for all employees.
- Increased production efficiency by optimizing plant layout and implementing process improvements.
- Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
- Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Coordinated plant expansions and upgrades to accommodate increased demand while minimizing disruption to ongoing operations.
- Analyzed incident reports to identify trends in workplace injuries or near-misses; implemented corrective actions accordingly.
- Collaborated with sales team to align plant capabilities with customer demands, fostering long-term business relationships.
- Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
- Managed budgeting and resource allocation, ensuring optimal use of funds for operational efficiency.
- Implemented quality control measures to reduce defect rates and enhance product quality consistently.
- Oversaw daily operations of Resin, Compounds and Colours plants.
- Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
Production Manager
Saint Gobain Isover
11.2022 - 03.2023
- Set clear objectives and goals for the Production operations and analyze plant performance to ensure constant improvement.
- Improve productivity through efficient management of Production and Labour costs and ensure they're within budget.
- Control of capital equipment and proper utilization of equipment under control.
- Management of and reporting on safety, production, quality, budgets, manpower, and industrial relations.
- Create and ensure safe working conditions at all times.
- Planning of manufacturing and management of all Glasswool & EPS manufacturing operations on site.
- Implementation of corrective actions where non-conformances were found during audits.
- Capacity planning and process optimisation.
- Manage staff requirements and direct the production team.
- Management of performance, training and development of staff.
- Defining and communication of WCM best practice, tools and techniques and developing external contacts.
- Drive process optimization and cost saving initiatives.
- Organise, monitor and control staff, shifts and overtime.
- Educating staff on principles of WCM.
- Maintain discipline and adherence to company policies.
- Actively lead the Production teams by being fully involved in the strategic development of the site against its corporate objectives.
- Build and manage a highly motivated and professional team who can meet the demands of a fast-paced challenging business environment whilst also ensuring the site meets demanding financial, Production and customer service and quality targets.
- Promote and support cross site networks to achieve consistency at Isover site.
- Set targets for each direct report using Strategy Deployment.
- Assess the Production Team's capability and ensure it is aligned to the delivery of Plant objectives.
- Train and develop the Production Team in line with identified gaps in capability and required succession planning.
- Ensure staff adherence and compliance to Principles of Conduct & Action, Corporate Governance and any other regulations required.
- Drive the Safety culture onsite.
- An active member of the SHE committee (16.2 appointee).
- Ensure SG EHS Management system is correctly implemented within the Production departments.
- Ensure all Ecotime, Winshuttle, ESS, SAP, and admin-related functions are timeously and accurately done as per correct procedures.
- Compiling monthly and periodic reports as required.
- Ensure implementation and adherence to WCM standards and closure of Projects within stipulated timelines.
Warehouse Manager
Johnson Matthey
01.2018 - 10.2022
- Manage the daily operations in the Receiving, Dispatch, Warehouse, and Slab area as well as ensure that there is continuous and adequate support to all Production Lines and Batching areas.
- Manage the function of Dispatch from a Logistics viewpoint at Johnson Matthey.
- Reports - Stock Reports, Waste inventory, Space utilization reports for Germiston, Cape Town, and Port Elizabeth Warehouses, Freight costs, individual/team performance reports, action-relevant points on the IAM report, action-relevant points from Audits, and action-relevant points from Plant Walk about's and month end Management reports.
- Systems - SAP functional in Receiving / Warehouse / Dispatch / Stock control and Deliveries.
- People - Time sheets are signed off on a monthly basis, coaching, and development through training programs, management of staff in line with company HR policy, motivate through the recognition process.
- Processes - ensure that all processes throughout the Warehouse Dept. are adhered to and revised at regular intervals.
- Organize, plan, and control the shipment of Catalyst scrap, Evaporator solids/solutions, and Lab Scrap for refining.
- Staff management and resource planning for receiving department.
- Ensure SOP's is in place for all processes and review annually.
- Plan and allocate suppliers to receiving slots per week per day.
- Compare actual stock received against pod and against approved purchase order in SAP.
- Quality inspections of goods received and best before date of stock must be checked.
- Vehicle inspection for all receipts completed and filed in the receiving file.
- Check and record vehicle and container seals and record accuracy.
- Receive stock into SAP and complete sub-contractor backflushing of works orders.
- Palletize stock correctly, shrink wrap and apply security tape before releasing the pallets received into the warehouse for storage.
- Ensure continuous evaluation and improvement of receiving activities.
- Liaise with waste contractors for scheduling waste removals and recycling in adherence with the Legislation requirements.
- Check and prepare pallets for long haul dispatch into the 3PL warehouses (Overseas, Durban, Port Elizabeth and Cape Town).
- Ensure adequate resources (staff, forklift, 8T and super link trucks) is available to load and dispatch shipments on time. (pre ordered trucks prior to shipment).
- Planning, organizing, and controlling recycling of all waste types at JM.
- Manage monthly stock take allocations, stock count, and reconciliation of stock.
- Attend training to receive accreditation in Shipment of Hazardous goods for sea freight, as well as road freight.
- Set up and manage Departments' KPI`s and measure and communicate performances; Down Time, Space utilization, stock/scanning accuracy, and Freight costs.
- Manage all warehouse staff in accordance with Johnson Matthey (Pty) Ltd. HR Policy.
- Set annual objectives of Staff and review progress and performance every 6 months as per the HR requirements.
- Ensure that Training and Development is done for all Warehouse Staff.
- Set up and manage the Warehouse Dept. Budgets.
- Offer 24/7 support to all Warehouse Staff and Shifts.
- Manage and communicate Storage space availability in all Warehouses, JM Germiston, PE Warehouse Cape Town Warehouse.
- Ensure that all stock received at the JM Warehouse is released and labeled within the required timelines.
- Carry out monthly LPA Continuous Improvement Audits throughout the Warehouse.
- Represent the Warehouse Department on all EHS issues.
- Ensure that the stock accuracy at all the Warehouses is at 98.8%.
- Facilitate the communication channels ensuring data/feedback is communicated in a factual and professional manner at all times.
- Ensure a timeous flow of information to the Dispatch Coordinators to support on-time delivery to our customers.
- Prepare monthly / weekly reports as required by management.
- 4 years Industrial Relations experience (Chairing Hearings, Disciplinary Action, Attending CCMA, Initiating Hearings, Investigations).
Production Manager (Acting)
Johnson Matthey
08.2016 - 09.2018
- Overall management of the Auto Catalyst Production Department, which includes all PC production lines, Line 11, Line 13, and Line 14 including the Metallic Cleaning Line.
- Direct and coordinate the production of auto catalysts, liaising with all service/ support departments, to ensure the product is produced to deliver the correct quantity and quality within specification, on time, and every time within budget constraints.
- Continuous improvement of people, plant, and equipment to optimize efficiency, operational effectiveness and minimise wastage.
- Control and tracking of all PGMs in the Auto Catalyst Production Department.
- Plant capacity planning, budgeting, and involvement in Capital Projects (defining, justifying, specifying, operational commissioning and its operation).
- Member of JMSA Manufacturing Team, focusing on systemic, continuous improvement, and strategic issues.
- Meet or exceed annual objectives and targets.
- Delegate objectives as appropriate and facilitate employee compliance through the HR systems, procedures, and procedures in place.
- Ensure SMART project methodologies are optimized in all production areas, and that use of the methodologies is sustained into the future.
- Interview, select and adequately train employees to meet production, quality, and housekeeping standards.
- Succession planning - adequately train senior employees to ensure the smooth running of all responsibilities in their absence.
- Coach and develop employees in line with the skills development and equity acts and anticipated future business needs.
- Ensure Personal Development Plans are in place for all your direct reports including other members of your teams.
- Conduct at least twice-annual appraisals with all direct reports and ensure all subordinates are trained in appraisals and conduct appraisals with relevant employees to deadlines agreed.
- Compliance with ISO/ TS 16949 standards and all other relevant and prescribed business standards.
- Manage Plant efficiency through Continuous Improvement through CI Engineers with clearly identified projects, using Improvement Tools (Kaizens, Problem-Solving Tools, SPCs, 5S, and Lean Manufacturing) and measuring ROI.
- Be involved in defining and justifying the reduction or elimination of factors contributing to reject production and quarantines.
- Manage and control all customer-specific specifications and ensure requirements are met.
- Ensuring compliance with all ISO standards, OSH Act, and all customer audit requirements.
- Manage and Control PGM Control System to ensure accountability for all PGM's at all stages of the process in Production Lines, and maintain average PGM loadings on all parts produced.
- Ensure adherence to EHS Standards, Policies, and Procedures and implementation at all levels.
- Create a safe work environment for all staff and instil EHS practices among employees.
- Manage all collation and storage of production data and generation of production reports accurately and timeously.
Production Superintendent
Johnson Matthey
12.2010 - 07.2016
- Accountable for meeting weekly production targets as per the production line plan by working through the team members on shift.
- Ensure that the day-to-day management of staff is done on a shift-by-shift basis so as to ensure there is sufficient shift cover, ensure adequate training for new staff, handling leave for engineers, etc.
- Troubleshooting: provide the necessary support to staff on shift so as to ensure minimal CSF process problems that may result in unnecessary downtime and compromised quality, handling mass balance issues.
- Project coordination, i.e., Ensuring follow-up of current projects, approval of new projects, and timing of projects.
- Ensure effective training of all subordinates, i.e., Operators and engineers.
- Conform to company safety and environmental requirements by ensuring that all CSF personnel adhere to procedures at all times. Zero man-hours lost due to injury.
- Zero non-conformance to legal requirements (ISO14001).
- Ensures that staff conforms to company's quality and performance standards and meet or exceed the set objectives.
Plant Co-ordinator
Johnson Matthey
05.2009 - 11.2010
- Manage and supervise Junior Engineers, Line Leaders and Operators.
- Ensure the required training is identified, provided and attended.
- Ensure that production targets are met.
- Ensure that company Health, Safety and Environmental policies are adhered to.
- Liaising with other departments in order to meet production targets.
- Control the usage of CSF raw material on the production line, optimise the use of equipment and ensure that the highest quality standards are maintained at all times on the shifts.
- Ensure that the production schedules are adhered to.
- Co-ordinating commissioning of equipment.
- Control the usage of CSF raw material on the production line, optimise the use of equipment, and ensure that the highest quality standards are maintained at all times.
- Meeting Daily production targets through the growth and improvements of the production area in line with the TPM and 5S continuous improvements methodologies frameworks.
Batching Co-ordinator
Johnson Matthey
06.2006 - 04.2009
- Manage and supervise Senior Engineer, Junior Engineers, Line Leaders and Operators.
- Ensure the required training is identified, provided and attended.
- Ensure that production targets are met.
- Ensure that Health and Safety is adhered to.
- Liaising with other departments in order to meet production targets.
- Control the usage of raw material on the production line, optimise the use of equipment and ensure that the highest quality standards are maintained at all times on the shifts.
- Ensure that the production schedules are adhered to.
- Co-ordinating commissioning of equipment.
- Control the usage of raw material on the production line, optimise the use of equipment and ensure that the highest quality standards are maintained at all times on the shifts.
- Ensure that w/c is batched on time, and is passing ll specification according to production plan( quality of the product is within the customer specification).
Batching Engineer
Johnson Matthey
10.2003 - 06.2006
- Lead a dedicated team of batchers.
- Ensure that washcoat slurry is batched on time as per our production requirement.
- Ensure availability of washcoat to the production line.
- Ensure Environmental Health and Safety regulations are met.
- Identify and ensure that staff development is provided.
- Always grooming someone to become my successor.
- Liaise with other departments and problem-solving challenges encountered as an Engineer.
Production Engineer
Johnson Matthey
05.2001 - 10.2003
- To ensure that the precision coating process is operating optimally and on target.
- To ensure production of high quality catalyst, reduce rejects and maintain good housekeeping.
- Manage a team or teams of line leaders and operators.
- Has responsibility to ensure that PGM loadings are on target as per customer specification.
- Ensure that the line leaders and operators follow company quality policies, work instructions, procedures and health/safety rules and regulations at all times.
- Adhere to company Quality policies, specifications, work instructions and procedures to ensure that quality systems are upheld at all times.
- Carry out troubleshooting to ensure minimal processing problems that may result in unnecessary downtime and compromised quality.
- Planning, Organizing and controlling.
Intern
Johnson Matthey
03.2000 - 05.2001
Education
Total Productive Maintenance -
JMAC
01.2017 - 12.2017
Problem-Solving - undefined
In-house Course
01.2017 - 12.2017
Management Development Programme - undefined
University of Stellenbosch
01.2016 - 12.2016
B-Tech Operations Management - undefined
Vaal University of Technology
01.2014 - 12.2014
Project Management - undefined
University of South Africa (UNISA)
01.2012 - 12.2012
National Diploma Chemical Engineering - undefined
Vaal University of Technology
01.2002 - 12.2002
Skills
Production management
Number Of Dependents
3
Personal Information
- ID Number: 7601265527083
- Driving License: Code 10
- Marital Status: Not Married
Timeline
Plant Manager
Scott Bader
09.2024 - Current
Production Manager
Saint Gobain Isover
11.2022 - 03.2023
Warehouse Manager
Johnson Matthey
01.2018 - 10.2022
Total Productive Maintenance -
JMAC
01.2017 - 12.2017
Problem-Solving - undefined
In-house Course
01.2017 - 12.2017
Production Manager (Acting)
Johnson Matthey
08.2016 - 09.2018
Management Development Programme - undefined
University of Stellenbosch
01.2016 - 12.2016
B-Tech Operations Management - undefined
Vaal University of Technology
01.2014 - 12.2014
Project Management - undefined
University of South Africa (UNISA)
01.2012 - 12.2012
Production Superintendent
Johnson Matthey
12.2010 - 07.2016
Plant Co-ordinator
Johnson Matthey
05.2009 - 11.2010
Batching Co-ordinator
Johnson Matthey
06.2006 - 04.2009
Batching Engineer
Johnson Matthey
10.2003 - 06.2006
National Diploma Chemical Engineering - undefined
Vaal University of Technology
01.2002 - 12.2002
Production Engineer
Johnson Matthey
05.2001 - 10.2003
Intern
Johnson Matthey
03.2000 - 05.2001
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