Manufacturing Manager
PZ Cussons
Total years of experience :12 years, 2 Months
Responsible for End-to-End manufacturing and production planning in Dishwash Factory (Morning Fresh), Personal Care Factory (Wipes, Jellies, Pomade, Medicaments, Antiseptics, Perfumes, Creams & Lotions), and Detergent Factory with an annual budget of 3 billion naira ($6.8M) and a total headcount of 300. Accountable for Site Safety, Quality, Efficiencies, People, Cost, and Waste.
5 Direct reports (Production Managers and Production Planner)
6 Dotted Line Reports (Engr and QA)
● Ensured effective & efficient coordination of all manufacturing (production, Engineering, and quality) operations within the packaging plant and ensured, 3 years in a row, KPIs of plan achievement and adherence of 100%+-5% were actualized.
● Coordinated focused improvement teams, increasing OEE of soft wrap soap lines by 19% and flow wrap soap lines by 11%
● Successfully increased productivity of a new production line by over 400% from 600 cartons per day to 2900 cartons per day, reducing manpower from 45 persons to 17 and without capital investment using industrial Engineering approach.
● Initiated and executed Flexi-manning by developing multiskilled operators at finishing plant, reducing the number of staff by 12%
● Reduced changeover time from 11 hours to below 5hours using SMED techniques.
● Introduced faster and more efficient systems of material variance analysis which led to 65% reduction in stock variance in weekly and monthly stock taking activities.
● Developed, led, and motivated a multicultural manufacturing team of 4 managers, 90 staff and 27 contract staff.
● Prepared the annual budget for the department and ensure expenditure is in line with the budget.
● Scheduled and implemented 1:1 with team members to track performance and give feedback.
● Managed team and individual performance through regular reviews, monitoring objectives and ensuring development needs are identified and actioned.
● Ensured compliance on Good Manufacturing Practice (GMP) and Health, Safety & Environment (HSE) related issues and Environmental management System implementation within the Plant.
● Coordinated and drove sustainability of Continuous Improvement activities across the site’s five CI pillars of safety, quality, delivery, cost, and motivation towards achieving the factory’s long-term plan through the CI roadmap activities.
● Coached and facilitated CI trainings across site including but not limited to RCA, 5-Why, SMED, Gap Analysis, 5S and PDRI project teams.
● Delivered CI project savings to reduce Production Cost and improve margins.
● Focused improvement through drive and adoption of Lean Manufacturing Techniques
● Designed and implemented planned preventive maintenance model for effective and efficient maintenance of the production lines equipment to reduce emergency intervention.
● Effectively used condition-based monitoring for efficient planning and maintenance jobs scheduling, thereby, reducing mean time between critical equipment failures (MTBF) by 40%
● Optimized packaging lines to use 10% less energy, saving N2.3million annually per line
● Reduced engineering downtime from 21% to 8 % at the packaging plant.
● Successfully managed high valued project (500-900 million naira) for Electrical Infrastructure Upgrade.
● Managed a team of 19 maintenance technicians.
● Scheduled and implemented 1:1 with team members to track performance and give feedback.
● Planned and executed improvement projects justification, procurement, installation, and commissioning.
● Prepared annual maintenance budget and ensured compliance.
● Reviewed daily maintenance activities of team members.
● Championed all capacity upgrades feasibility study and implementation.
● Coordinated and drove sustainability of continuous improvement activities across the site’s five CI pillars of safety, quality, delivery, cost and motivation towards achieving the factory’s long-term plan through the CI roadmap activities.
● Coached and facilitated CI trainings across site including but not limited to RCA, 5-Why, SMED, Gap Analysis, 5S and PDRI project teams.
• Coordinated site utilities/services required to ensure provision cooling requirement from the chillers, steam from the boilers, compressed air, water supply, etc for production purposes at Aba and Port Harcourt sites.
• Planned and executed steam reduction / energy savings project across site, saving over N200million annually.
• Coordinated power production from the gas and diesel power plants.
• Formulated and facilitated Service Level Agreements which led to 99% utilities availability for production.
• Part of the functional team that transformed utility & Power plant operations by reducing downtime by 25% and saving 9million naira annually on in-house repair & maintenance.
• Improved technical competency level of team members from 58% to 89% performance rating, thereby, reducing the mean time to repair (MTTR)
• Successfully led the installation and Commissioning of 220TR water chiller, 2000L/s air dryer and 40m3/hour demineralization plant at the utilities plant.
• Ensured efficient usage of energy towards realizing the site’s KPI of Kwh/ton and steam/ton of soap produced.
• Ensured PPM and overhauling activities are carried out according to schedules.
• Continuously investigated and carried out root cause analysis for breakdown of equipment, trouble shooting and monitor performance of plants.
• Managed day to day maintenance / breakdown and operational activities
• Established safe working environment by implementing all required HSE policies and practices
Maintenance planning and scheduling
PPM and LLF maintenance
Ensure Production targets are consistently achieved
Condition-based monitoring of production equipment
Behavioral-based safety coordination
● Carried out daily condition monitoring of various pumps, turbines, compressors, and other rotating equipment.
● Part of the maintenance team responsible for installation of new plant and equipment
● Carried out routine and scheduled maintenance on the Fuels plant, Carbon black plant and Powerplant & Utilities
● Ensured work orders are processed and the right materials are requested.
● Assisted at the central maintenance planning to ensure downtimes are minimized.