THOMAS STEVENS
SENIOR MANAGEMENT
Pretoria
Summary
I am a highly motivated and results-oriented Program Manager with a proven track record in inspiring teams to achieve exceptional outcomes. With extensive experience in Plant Operations and industrialization, I specialize in implementing quality management systems and optimizing production schedules. My expertise in lean manufacturing and process enhancement positions me to make a significant contribution to your team. I am eager to leverage my skills to drive success within your organization.
Overview
22
22
years of professional experience
2
2
years of post-secondary education
1
1
Language
Work History
Lead Program and Operations Management Consultant
Automotive Investment Holding
01.2024 - 03.2024
- Supplier audit and investigation into Silencer factory Production operations In Norway
- Assess current production practices and processes including quality systems, machine capability and capacity
- Provide report on findings and provide recommendations and Solutions for implementation
- Conducted supplier audits to enhance production efficiency at Silencer factory
- Analyzed quality systems for compliance, boosting overall product standards
- Evaluated machine capability and capacity, identifying areas for improvement
Program Manager
Global PAC Group
08.2024 - 12.2024
- Spearheaded the production ramp-up and launch plan for the High Density Tote Pod (HDTP Rack), ensuring stabilization of production and optimizing throughput through effective management of temporary labor
- Defined program deliverables, set critical milestones, and established daily objectives to drive project success
Program Manager
Specialized Mechanical Engineers
05.2024 - 08.2024
- Project Management Overview for HVAC Production Stabilization Contract
- Stabilize production of Heating, Ventilation and Air Conditioning (HVAC) systems for Gibela Commuting trains
- Developed Short Interval Controls for measuring daily throughput, cycle time, and line balancing
- Stabilized HVAC production for Gibela Commuting trains, boosting efficiency
- Implemented Short Interval Controls to track daily throughput and cycle time
- Optimized line balancing, leading to improved workflow and reduced delays
Lead Program and Operations Management Consultant
Automotive Investment Holdings
05.2023 - 05.2024
- Conducted a Bankable Feasibility Study for factory set-up in the Netherlands, defining critical factory requirements and establishing strategic tooling and investment parameters
- Developed a comprehensive project timeline and outlined milestones and deliverables to ensure successful project execution
- Spearheaded the industrialization of a new automotive modification center in the USA, focusing on optimizing factory layout and aligning resource requirements
- Executed Time and Motion Studies to refine production processes and develop accurate production models and simulations for efficient workstation requirements
- Championed team development initiatives for implementing an automated production monitoring system, enhancing operational efficiency
- Created a detailed workstation gatekeeping assembly build book to standardize processes and improve workflow
- Delivered actionable recommendations for operations improvement and conducted thorough supplier audits to boost production quality and efficiency
Program Manager
PAC Group
01.2022 - 05.2023
- Lead program for the establishment of a greenfield EV factory in Pryor Creek Oklahoma Mid-America Industrial Park
- Co-ordinate all program initiatives which include the Simultaneous Engineering Activities of Core and shell (Factory) construction, Turnkey Paint Shop, Body Shop, Battery assembly and final assembly
- Directed repurposing of assembly plant for India OEM, boosting efficiency
- Managed pre-construction for Amazon Warehouse, ensuring timely permits
- Led EV factory establishment in Oklahoma, meeting critical project timelines
- Coordinated engineering activities, delivering key program milestones on schedule
Project Manager
Automotive Investment Holdings
01.2021 - 12.2021
- Project manager leading the Tool and Die engineering expert teams in USA, Canada, and China for the new P703 Ford Ranger
- Led cross-country expert teams for P703 Ford Ranger project
- Streamlined communication across USA, Canada, and China teams
- Achieved project deadlines, enhancing product launch efficiency
- Drove innovation, improving tooling processes by 30% for cost savings
Independent Snr Logistics Consultant
Independent
02.2021 - 07.2021
- Conducted comprehensive supplier readiness logistics audits for Daimler (MBSA) ahead of SOP for the W206 new model, delivering strategic recommendations for supply chain optimization across all electrical suppliers
BU Consultant Head
ACCU Services
01.2020 - 09.2020
- Develop the business case as BU head for ACCU service (Pty) Ltd and set up of the 'New South Africa Country service provider' to deliver premium quality containment service to BMW South Africa manufacturing Plant
- Led business case development for ACCU service, boosting market presence
- Established 'New South Africa' service provider for BMW's premium quality
- Delivered top-tier containment services, ensuring operational excellence
- Achieved measurable impact on service delivery and client satisfaction
Independent Consultant
P3
09.2019 - 12.2019
- Streamlined production processes for plastic injection molded parts, enhancing efficiency and reducing lead times
- Optimized warehousing strategies to maintain adequate buffer stock of critical components
- Implemented in-sequence line side delivery to ensure timely and reliable distribution of materials
Program Operations Manager
KLT Automotive And Tubular Products
06.2018 - 06.2019
- Conducted comprehensive reviews of CAPEX requirements while effectively maintaining and monitoring OPS expenditure to ensure financial efficiency
Platform (Project Launch) Manager / R&D
IVECO South Africa Works
05.2016 - 06.2018
- Lead the commercial key account of the Afriway commuter bus
- Lead all engineering activities in design including budget planning and engineering release of new designs, product improvements facility development of IVECO manufacturing facility
- Drove commercial success for Afriway's key account, boosting revenue
- Led engineering design initiatives, ensuring timely product releases
- Managed budget planning for new designs, optimizing cost efficiencies
- Enhanced IVECO's manufacturing facility, improving production capabilities
Operations Manager and Quality Auditor
Booyco Engineering
08.2015 - 04.2016
- Managed supply chain and logistics
- Raw material through to finished goods
- This incorporated supplier quality and in plant manufacturing quality awareness
- Managed the accreditation of ISO 9001:2008, and recertification of ISO 14001
- Optimized supply chain from raw materials to finished goods delivery
- Enhanced supplier and manufacturing quality, boosting product reliability
- Achieved ISO 9001:2008 accreditation, ensuring quality excellence
- Successfully led ISO 14001 recertification, promoting sustainability efforts
Manager Engineering and Product Development
UD Trucks Southern Africa PTY LTD
12.2010 - 11.2014
- Manager GTD (Global Truck Development) Engineering for all new and special Truck conversions SVO Special Vehicle Orders / SVR (Special Vehicle Request)
- Approve the Creation of BOM's for the release of all system components
- Led GTD Engineering for high-demand truck conversions, enhancing market appeal
- Streamlined SVO and SVR processes, boosting efficiency and client satisfaction
- Approved BOM creation for rapid release of system components, driving production
- Optimized special vehicle requests, resulting in increased sales and revenue growth
Manager Engineering / Quality
Optimal Energy
06.2008 - 11.2010
- Led engineering team in chassis development, boosting efficiency and integration
- Established automotive design standards, enhancing product consistency and quality
- Implemented corrective action plans, reducing nonconformance rates significantly
- Collaborated with marketing to align engineering specs with market demands
Manager Vehicle Engineering and Test Operations
Ford Motor Company
08.2002 - 05.2008
- Spearheaded all New Product Model Launch Vehicle Engineering Projects, driving innovation and efficiency
- Established accurate Project Cost Assumptions to ensure financial integrity and optimal resource allocation
- Facilitated and managed all BIW (prototype) builds for new models, ensuring timely delivery and quality standards
- Developed and enforced OHSA compliance, fostering a culture of safety and adhering to ISO 9000/14001/18001 and TS 16949 standards
- Optimized processes to streamline operations in Vehicle Engineering, enhancing product development, logistics, and lean inventory management
- Led capital investment initiatives for facility and parts warehousing development, enhancing capacity in Vehicle Engineering
- Oversaw CAPEX and tooling expenses, efficiently managing a budget of R500K ZAR PA
- Chaired the Safety Committee for Vehicle Engineering Test Operations, implementing rigorous safety policies and corrective actions to meet 18001 standards
- Managed Quality Operating Systems (QOS) in alignment with corporate standards, applying methodologies like APQP, G8D, FMEA, and ISIR PSW
- Implemented and co-managed the vehicle engineering TS 16949/ISO 9001 and ISO 14001 systems for continuous improvement and compliance
Education
HIGHER NATIONAL DIPLOMA - Electrical Engineering (Light Current)
Tshwane University Of Technology
Pretoria, South Africa 01.1992 - 12.1992
HIGHER NATIONAL CERTIFICATE - Management Development Program
University Of South Africa
Pretoria, South Africa 01.2000 - 12.2000
Skills
General Management
Manufacturing Management
Operations Management
Sheet metal Welding
Paint Plant Operations
Technical Investigations
Production Management & Planning
Quality Management
Root Cause Analysis
Risk Management & Identification
Health & Safety
Supplier Development & Management
Resources Management
Crisis & Change Management
Implementation Management
Timeline
Program Manager
Global PAC Group
08.2024 - 12.2024
Program Manager
Specialized Mechanical Engineers
05.2024 - 08.2024
Lead Program and Operations Management Consultant
Automotive Investment Holding
01.2024 - 03.2024
Lead Program and Operations Management Consultant
Automotive Investment Holdings
05.2023 - 05.2024
Program Manager
PAC Group
01.2022 - 05.2023
Independent Snr Logistics Consultant
Independent
02.2021 - 07.2021
Project Manager
Automotive Investment Holdings
01.2021 - 12.2021
BU Consultant Head
ACCU Services
01.2020 - 09.2020
Independent Consultant
P3
09.2019 - 12.2019
Program Operations Manager
KLT Automotive And Tubular Products
06.2018 - 06.2019
Platform (Project Launch) Manager / R&D
IVECO South Africa Works
05.2016 - 06.2018
Operations Manager and Quality Auditor
Booyco Engineering
08.2015 - 04.2016
Manager Engineering and Product Development
UD Trucks Southern Africa PTY LTD
12.2010 - 11.2014
Manager Engineering / Quality
Optimal Energy
06.2008 - 11.2010
Manager Vehicle Engineering and Test Operations
Ford Motor Company
08.2002 - 05.2008
HIGHER NATIONAL CERTIFICATE - Management Development Program
University Of South Africa
01.2000 - 12.2000
HIGHER NATIONAL DIPLOMA - Electrical Engineering (Light Current)
Tshwane University Of Technology
01.1992 - 12.1992