Thami Khanyile
Production Lead
Johannesburg
Summary
Dynamic Production Foreman at Lynca Meats, skilled in lean manufacturing and conflict resolution. Spearheaded continuous improvement initiatives, enhancing operational efficiency and boosting team morale. Proven track record in strategic planning and problem-solving, resulting in increased on-time delivery rates and a safer workplace environment. Committed to fostering a culture of excellence and accountability. Experienced leader with strong background in guiding teams, managing complex projects, and achieving strategic objectives. Excels in developing efficient processes, ensuring high standards, and aligning efforts with organizational goals. Known for collaborative approach and commitment to excellence.
Overview
23
23
years of professional experience
1
1
Certificate
3
3
years of post-secondary education
Work History
Production Foreman (Head of the Deboning Plant)
Lynca Meats
Meyerton, Johannesburg
07.2021 - 01.2025
- Increased on-time delivery rates through effective scheduling, planning, and coordination among departments.
- Enhanced production efficiency by streamlining processes and implementing lean manufacturing principles, achieving a 100% PvA output, with 98% schedule adherence
- Conducted root cause analysis for identifying recurring issues in the production line, leading to lasting solutions for improved overall performance.
- Developed comprehensive safety procedures for workplace hazard reduction, resulting in fewer accidents and injuries.
- Reduced machine downtime through regular equipment maintenance and staff training on proper usage.
- Organized weekly meetings with team members to review progress, address concerns, and set goals for continued improvement.
- Spearheaded continuous improvement initiatives to identify areas of potential cost savings and process improvements.
- Assisted upper management with strategic planning to meet long-term objectives in productivity and profitability growth.
- Improved product quality by closely monitoring production processes and enforcing strict quality control measures.
- Evaluated employee performance regularly, providing constructive feedback for professional growth opportunities.
- Analyzed production data and prepared reports for senior management.
- Created and oversaw production schedules and adjusted as needed to meet deadlines.
- Enforced health and safety protocols to promote safe working environment.
- Scrutinized production output and identified areas for improvement, resulting in a 10% Yield improvement.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Implemented quality control system to review products against technical specifications and corporate standards, resulting in 60% reduction in Customer Complaints
Production Unit Manager (Pack)
Unilever SA
Boksburg, Johannesburg
06.2019 - 09.2020
- Optimized staffing levels by monitoring the packing department needs and making data-driven adjustments to scheduling as necessary.
- Promoted a culture of safety within the unit by enforcing strict adherence to protocols and guidelines.
- Evaluated employee performance regularly for professional growth opportunities, accountability measures, and feedback-driven improvement strategies.
- Enhanced operational efficiency, redesigning workflow processes.
- Coordinated cross-functional teams to address complex project challenges, ensuring timely completion.
- Drove significant improvements in team morale and engagement, organizing motivational events and recognition programs.
- Achieved top employee performance ratings, fostering environment of accountability and support.
- Fostered culture of continuous improvement, encouraging innovation and adaptability among team members, resulting in 8% OEE improvement
- Spearheaded initiatives to enhance product quality, collaborating closely with quality assurance team.
- Fostered culture of excellence and continuous improvement, organizing regular team-building activities.
- Enhanced safety protocols, leading to record-low number of workplace incidents, where a million incident free man hours were achieved.
- Boosted customer satisfaction by ensuring high-quality service standards were consistently met.
- Implemented customer (internal downstream departments) feedback system to identify areas for improvement and act upon them.
- Designed and introduced leadership development, coaching and team management model, resulting in promotion of employees into increased levels of responsibility.
- Recruited, hired and trained all staff, providing direct supervision, ongoing staff development and continuing education to employees.
Production Shift Unit Manager (Pack)
Unilever SA
Boksburg, Johannesburg
04.2015 - 06.2019
- Optimized staffing levels by monitoring unit needs and making data-driven adjustments to scheduling as necessary.
- Evaluated employee performance regularly for professional growth opportunities, accountability measures, and feedback-driven improvement strategies.
- Fostered culture of continuous improvement, encouraging innovation and adaptability among team members.
- Enhanced safety protocols, leading to record-low number of workplace incidents.
- Fostered culture of excellence and continuous improvement, organizing regular team-building activities.
- Enhanced team productivity by implementing efficient work schedules and providing continuous training.
- Coordinated cross-functional teams to address complex project challenges, ensuring timely completion.
- Reduced downtime by overseeing maintenance and timely upgrade of equipment.
- Led the shift to exceed performance goals through strategic planning and effective resource allocation.
WCM/TPM Facilitator
Unilever SA
Boksburg, Johannesburg
08.2012 - 03.2015
- Enhanced TPM/WCM programme effectiveness by collaborating with colleagues to review and revise the approach strategy regularly, across all pillars.
- Delivered high-quality training sessions, ensuring participants developed a thorough understanding of the subject matter, specific to a TPM/WCM pillar.
- Built rapport with diverse groups of stakeholders by demonstrating empathy, active listening skills, and cultural competence during facilitated sessions, coaching and training.
- Contributed to improved team performance by facilitating workshops on communication, collaboration, and problem-solving techniques.
- Identified areas in need of improvement and implemented solutions.
- Promoted continuous learning within the organization by sharing best practices and lessons learned from various facilitation experiences and achievements from other Unilever sites.
- Facilitated breakthrough moments for participants with carefully crafted group continuous improvement activities, across each pillar.
- Led cross-functional teams in brainstorming sessions, driving innovation and creative problem-solving.
- Conducted post-event evaluations to gather feedback and implement improvements for future audit improvements.
- Empowered participants to apply learned concepts in their professional and personal lives through practical application exercises.
- Conducted regular pillar audits to identify pillar specific challenges and areas of focus.
Make Supervisor (Wet and Dry Rework Optimisation)
Unilever SA
Boksburg, Johannesburg
10.2009 - 07.2012
- Oversaw daily operations of the Wet and Dry rework plants, ensuring smooth workflow and increased inclusions into main stream.
- Resolved conflicts among team members promptly, maintaining a harmonious working environment conducive to productivity.
- Identified operational inefficiencies and implemented corrective measures to increase effectiveness.
- Developed staff skills through targeted training programs, resulting in improved performance and career growth opportunities.
- Implemented safety protocols to minimize workplace accidents and maintain compliance with industry standards.
- Achieved significant improvements in operational efficiency, introducing and enforcing quality control measures.
- Enhanced operational workflow, identifying and eliminating bottlenecks in daily procedures.
- Negotiated with vendors to secure cost-effective contracts, resulting in significant budget savings.
- Fostered culture of continuous improvement, encouraging team to suggest and implement process enhancements.
- Frequently inspected production area to verify proper equipment operation.
- Developed effective improvement plans in alignment with goals and specifications.
- Cultivated positive relationships with vendors to deliver timely and cost-effective supply of services.
Soap Maker (Senior Process Operator)
Unilever SA
Maydon Wharf, Durban
03.2008 - 09.2009
- Monitored and Maintained Soap manufacturing process parameters in the manufacturing control room
- Studied quality analysis and adjusted the parameters accordingly, to achieve the desired quality specifications
- Owned and drove the Continuous Improvement activities to reduce downtimes.
- Managed the equipment/asset utilization, ensuring rotation, to allow for maintenance activities and avoid "Force Majore".
- Maintained compliance with health, safety, and environment practices.
- Isolated and prepared equipment for corrective and scheduled maintenance procedures.
- Managed pre-commissioning and commissioning activities.
- Served as a technical expert on process operations, contributing to the troubleshooting efforts for complex issues impacting production output and quality.
Assistant Soap Maker
Unilever SA
Maydon Wharf, Durban
04.2004 - 02.2008
- Assisted the Senior Process Operator by being physically stationed in the plant, for opening and closing of manual valves, whilst he controlled the parameters in the plant's control room.
- Performed Autonomous maintenance activities (Cleaning, inspections and lubrication) in the plant.
- Performed sampling, laboratory testing and analysis of final manufactured product (neat soap).
- Performed sampling, laboratory testing and analysis of reworked product, before inclusion into the main process.
- Updated Continuous Improvement Activities' boards, situated in various sections of the plant
General Operator
Unilever SA
Maydon Wharf, Durban
05.2002 - 03.2004
- Troubleshot equipment issues swiftly, minimizing disruptions to overall productivity levels on the factory floor.
- Operated various machines and equipment safely, adhering to strict safety protocols at all times.
- Reduced waste and increased recycling/reworking efforts for a more sustainable working environment.
- Supported continuous improvement initiatives that led to enhanced operational efficiency throughout the facility's production lines.
- Enhanced product quality through diligent monitoring of raw materials, machinery performance, and end products.
- Conducted routine maintenance checks on machinery, ensuring optimal performance and reducing downtime due to malfunctions.
- Maintained organized work area by cleaning and removing hazards.
- Organized and prepared workstations and materials needed for operations to maximize productivity.
- Inspected products and machines to maintain quality and efficiency.
- Assembled products according to changing daily work orders and specific customer needs.
- Examined incoming materials and compared to documentation for accuracy and quality.
Education
Certificate - Chemical Plant Operations
Scientec College
Durban 02.2009 - 06.2009
N3 Certificate - Mechanical Engineering
KZN Coastal FET College
Durban 04.2003 - 04.2005
1 Year Diploma - Basic Electronics, Radio And TV Repairs
MedTech Training College
Durban 03.1997 - 11.1997
Skills
Lean manufacturing
Accomplishments
- Gained a vast Labour Law and Leadership understanding and experience through my involvement in the Unilever Durban site Shop Steward Council, where I served as a Secretary within the Executive Council.
- I held various Leadership roles in Unilever for over 15 years, starting as a Team Leader through to TPM/ WCM Facilitator (Facilitating Continuous Strategies and Lean manufacturing principles across 9 pillars of various functions) and finally involved in Production as a Packaging Unit Manager.
- In 2018, I had an opportunity, amongst a team of Engineers, to be part of FAT (Factory Acceptance Test) delegation in France, representing both Production and Continuous Improvement (ManEx - Manufacturing Excellence) segments.
- Upon joining a Pork Industry in 2021 (a completely different industry all round), I introduced a turn-around strategy in the 'troubled' Deboning Department, which saw an all round improvements on all KPIs (Key Performance Indicators). The Department became the pioneer of change with all strategies and Leadership strategies rolled over to other Departments.
- I was continuously exposed to skills enhancements through various trainings, throughout my Leadership journey. Training on 'Emotional Inteligence and Personal Mastery', amongst other trainings stood out the most for me and boosted my self- awareness as a Leader.
Certification
FSSC version 5.1 to 6 conversion workshop
Work Preference
Work Type
Full TimeWork Location
On-SiteImportant To Me
Company CulturePersonal development programsWork Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Quote
Good to Great, always
Own
Languages
English
Bilingual or Proficient (C2)
Afrikaans
Elementary (A2)
Interests
Calming music (Soul)
Timeline
FSSC version 5.1 to 6 conversion workshop
07-2023
Production Foreman (Head of the Deboning Plant)
Lynca Meats
07.2021 - 01.2025
Production Unit Manager (Pack)
Unilever SA
06.2019 - 09.2020
Production Shift Unit Manager (Pack)
Unilever SA
04.2015 - 06.2019
WCM/TPM Facilitator
Unilever SA
08.2012 - 03.2015
Make Supervisor (Wet and Dry Rework Optimisation)
Unilever SA
10.2009 - 07.2012
Certificate - Chemical Plant Operations
Scientec College
02.2009 - 06.2009
Soap Maker (Senior Process Operator)
Unilever SA
03.2008 - 09.2009
Assistant Soap Maker
Unilever SA
04.2004 - 02.2008
N3 Certificate - Mechanical Engineering
KZN Coastal FET College
04.2003 - 04.2005
General Operator
Unilever SA
05.2002 - 03.2004
1 Year Diploma - Basic Electronics, Radio And TV Repairs
MedTech Training College
03.1997 - 11.1997
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