Chemical Engineering Engineer

*

CV for Steady Mukondiwa (AMIChemE)

Qualifications

MBA; M.Sc. Chemical Engineering; B.Eng. Chemical Engineering; World Class Manufacturing (WCM) Professional Maintenance (PM) and Focused Improvement (FI) Practitioner Motivation

I am a seasoned results focussed multi-skilled Engineering and Management Professional with 17 years hands-on postgraduate technical and business experience in various heavy manufacturing plants up to integrated industrial sector level. I have advanced management experience implementing innovative process systems in lean/world class manufacturing (WCM) businesses at levels ranging from functional process engineering to senior strategic roles across value streams in individual businesses and in value chains at sectoral levels. Am responsible for centralised planning and stakeholder engagement working with employer associations, trade unions, government departments and various local and international support organisations in line with industry productivity and competiveness initiatives. I have led operational strategy formulation and implementation in heavy manufacturing processes in glasswool manufacturing, catalytic convertors manufacturing, minerals processing and refining, fibre and chipboard manufacturing and in clothing and textile manufacturing sectors. I have acquired extensive experience in key operational functional roles including core manufacturing process engineering, process and product development, process management and integration, business optimisation/sustainability, value chain and supply chain strategy focusing on optimising sectoral productivity and competitiveness. Successfully led and optimised automated/robotic operated manufacturing processes and have good application knowledge of artificial intelligence in manufacturing. Led multi-disciplinary teams in development and deployment of operating procedures in technical areas of efficient manufacturing, safety, security and business continuity, plant design and operations, human capital optimisation methodologies. I have experience in implementation of integrated ISO 9001, ISO 14001, ISO18001 and ISO 50001 systems in diverse manufacturing processes. Have proven leadership effectiveness in the current role as Director of Productivity and Training applying process engineering tools, strategy formulation and implementation, WCM/lean knowledge and operational research competences in diagnosing the sectoral challenges/opportunities and developing relevant interventions in line with identified gaps. I believe in continuous skills development and supporting development of team members, building organisational capacity to meet the culture of sustainable high performance and innovative businesses. I am a balanced life family man, a self-discovered active road running enthusiast also using the acquired workplace experience and professional knowledge in social life as a member of Church’s finance, strategy and ethics committee. Personal information:

Surname / First name: Mukondiwa Steady

Addresses: 15 Van der Merwe Street, Boksburg West ext. 1, 1459, Gauteng Telephone Work: +27-21-460-****/ +27-11-402-**** Mobile: +27-83-864-**** E-mail adcnnr@r.postjobfree.com adcnnr@r.postjobfree.com Date of birth 09 July 1976

Gender Male

Current Position Director of Productivity and Training, National Bargaining Council for Clothing Manufacturing Industry, National Role in South Africa

Current Salary

Notice Period

Transport

Reasons for wanting to leave

R915k/annum CTC plus 13th cheque performance linked bonus Calendar month

Own vehicle

Having accomplished the primary objective of setting up a vibrant sustainable clothing manufacturing sector focussed productivity and training institute and implementing improvement initiatives/interventions and best practices adopted from the broader manufacturing sector. I am excited to consider a leadership role which aligns with my acquired multiple skills, technical process engineering and hands on strategy development and implementation skills. Current role is a bit unstable as it is dependent on government project funding. Desired employment /

Occupational field

Senior/Middle Management role in Commercial Business, Manufacturing, Consulting, Processing Operations, Financial Sector or Government Sector 17yrs Management & Process

Engineering work experience

Period 04/2016 to current (Contract Position)

Occupation or position held Director – Productivity and Training (five direct subordinates and +100 industry service providers/suppliers/consultants/researchers working with +850 factories) Main activities and responsibilities Diagnosing the state of sector, benchmarking performance nationally and internationally and leading the crafting and implementation of productivity and skills improvement strategies implementable at factory and sectoral level.

2

Leading and development and implementation of departmental plans in agreement with management Committee

Scoping and aligning sector strategic manufacturing sustainability and growth initiatives with the national development plan (NDP) focusing on inclusive growth and collective efficiency.

Developing collaborative sector productivity and skills development interventions with ILO, SES, FP&M SETA and DTI agents, namely SEDA, IDC, Productivity SA, Proudly SA and TIA

Financial management and budgeting, justifying and sourcing of sector improvement funding.

Developing industry codes of best practice and managing subordinates and consultants through performance KPIs and SLAs. Working with a team of Industrial Engineers/work-study officers and various business expert service providers/suppliers/researchers working on improving the manufacturing systems for enhanced industry productivity

Leading manufacturing innovation, knowledge/skills and technology road-mapping, optimising human and machine work related processes including artificial intelligence and robotics in the manufacturing environment, worker health, safety behaviour and zero injury, design for safety.

Promoting adoption of WCM/lean systems as a standard for manufacturers and managing the industry’s WCM route map, establishing a standard benchmarking index, aligning WCM KPIs to continuously improve Safety, Customer Service, Reliability, Quality, People Capability and Cost.

Developing an industry database to capture industry productivity metrics and supplier and service provider directory and performance rating system

Initiating programs for assisting development of efficient suppliers from previously disadvantaged groups and optimise their delivery output at world class quality standard

Optimizing the use of technology with people, harnessing the employer employee relationships to enhance productivity, building capacity on use of the workplace skills planning process

Stakeholder engagement and development of effective networks with external organizations including manufacturers/employers, trade unions, suppliers, service providers, academic institutions, government department and

Promoting the research needs of the sector to academic institutions for specialised diagnosis, identifying specialist service providers and collaborate to develop industry sustainability Achievements Leading centralised industry skills planning through development of an industry/sector skills development accord between employers, labour and supporting implementation through tertiary institutions. Motivating support from key government departments (FP&M SETA) to structure support for skills and technology projects to improve productivity in the industry and securing relevant funding.

Securing multi million Rand funding for enhanced skills development programme to train technology relevant skills and grow industry in line with the industry growth masterplan.

Successfully motivating for and securing funding convening the 1st ever industry/sector summit in April 2017 focussing on clothing manufacturing industry themed “Skills development – for a sustainable clothing industry and a 2nd industry skills development conference in April 2018 themed “sustainable skills development through empowered workplace skills committees”

Successfully motivating for, securing funding and convening a value chain conference of 500 key stakeholders in September 2017 from the Clothing, Textile, Footwear and Leather (CTFL) value chain to strategise on leveraging value chain collaborations countering possible impacts of credit downgrade to sector. Continuously adopting value chain approach in industry interventions.

Conducting an industrywide technology and manufacturing systems diagnosis and international benchmark on technology and skills to inform a five year industry improvement roadmap integrating technology change in line with 4th industry revolution and optimised training models.

Implementing a supply chain intervention leveraging the relationship between manufacturers and retailers and the broad adoption of WCM customer focus systems to improve competitiveness and leading to an integrated value chain approach to sector turnaround.

Developing two WCM models in collaboration with Productivity SA, one model for entry level immature factories and another model for factories with mature systems turned around fifteen factories with a total of +7000 employees applying this WCM tools and strategy implementation.

Establishing collaborative technical partnership with ILO to implement their flagship SCORE programme in the clothing manufacturing industry and securing funding for pilot implementation in 15 factories.

Name and address of employer National Bargaining Council for Clothing Manufacturing Industry, 350 Victoria Street, Salt River, 7925, Cape Town, South Africa

Type of business or sector

National Bargaining Council for Clothing Manufacturing Industry 3

Period 10/2012 to 03/2016

Occupation or position held Senior Process Engineer – Process Department Head (four direct subordinates + 80 factory process operation employees)

Main activities and responsibilities Managing the Process Engineering Department and supporting the glasswool manufacturing process stability and all manufacturing chemical engineering functions and critical process variables to maximise output and meet sales and customer requirements

Integrated human and machine work related processes optimisation and innovation focussing on enhanced process safety, work environment and automation for enhanced productivity

Manufacturing cost control and working capital management through innovative optimisation of process strategic consumables supply, process raw materials supply and improved service delivery without compromising output

Leading the manufacturing process function/role of the strategic sourcing of the supply/value chain and managing process technical side risks to safeguard business continuity

Working as part of the team of process experts in the global team of Saint Gobain Isover’s global consortium of insulation process plants and participating in the group’s global raw materials and consumables sourcing leveraging South Africa’s contribution in its available materials and expertise

Contract life cycle management for critical process consumables and raw materials, eliminating value leakage through involvement in managing service level/performance during contracting.

Managing the inventory of factory’s critical raw materials and engineering consumables which form part of the strategic global inventory of critical resources for integrated risk reduction and working capital control

Applying WCM cost deployment model based on use of quantifiable data to measure unit operations/categories in the business value stream to identify loss areas and prioritise relevant improvement initiatives

Allocating responsibility and managing performance of subordinates (Process Engineers) to effectively manage production process in line with company objectives

Benchmarking the manufacturing process using key KPIs/benchmarking index with sister/similar plants towards achieving best in class status

Managing major process unit maintenance projects including full furnace rebuilds, partial refractory linings replacement, calcination ovens and boiler maintenance

Budgeting and control of process annual expenses for raw materials and process consumables and integrating this to the business procurement plan

Participating in optimisation of operations Opex and Capex, both for short term and long range planning so as to maintain desired productivity and maintain best in class competitiveness

Ensuring that manufacturing, safety and housekeeping standards are maintained, creating a good safe working environment for all through HAZOP and HAZAN studies plus factory safety systems and awareness programs implementation

Championing the implementation of WCM green manufacturing systems at factory level and managing process projects aligning factory to global organization’s sustainability standards

Championing WCM Focused Improvement (FI) and Professional Maintenance (PM) systems implementation for improved productivity

Diagnosing process and implementing improvement initiatives and managing full project cycle from feasibility studies to effective implementation of identified improvement projects

Driving new product introduction with the global research team, optimisation and managing the materials master data process and bill of materials linking these to supply chain processes. Achievements Leading the Process Engineering team in developing and implementing basic process management systems and effective operator engagement in line with the WCM methodology achieving 12% reduction of production manufacturing cost in 2013 through implementation of various process optimisation and plant improvement initiatives and Springs plant voted the Best Improved Plant across Isover’s global plants for 2013.

My Process Engineering team was voted the best team in Saint-Gobain South Africa in 2014’s Pride Awards; I was runner up in Leadership category in Saint-Gobain South Africa for 2014. Name and address of employer Saint Gobain Isover, 2 Iron Road, New Era, Springs, Gauteng, South Africa Type of business or sector

Reason for leaving

Manufacturing – Technical Insulation and Glasswool Taking a developmental strategy development and implementation role for broader hands on knowledge application and career growth to broaden span of control and engagement within a different sphere industry

4

Period 03/2008 to 10/2012

Occupation or position held Principal Process Engineer (five direct subordinates and 40 factory process operation employees)

Main activities and responsibilities Management of all chemical engineering aspects of manufacturing plant and implementation of continuous process improvement initiatives and part of catalyst process development team

WCM/Lean manufacturing systems implementation and continuous improvement

Integrated human and machine work related processes optimisation including automation

Mentoring and training junior process engineers

Manufacturing process optimisation and cost control leveraging the group supply chain initiatives to reduce input costs and control working capital

Capital equipment project initiation and full project cycle management and implementation

Process design projects and supplier selection and contracting

Process mapping and manufacturing process KPI management

Operator technical process training and plant technical library development

Process troubleshooting and de-bottlenecking

Process technology and innovation management

Equipment sourcing, plant commissioning and technology exchange with sister plants

Process management systems implementation including FMEA implementation

Production scale up

Achievements Led continuous improvement team to reducing rejects from 3% to sustainable level below 0.6%. Same team improved process efficiency from 65% to sustainable level above +95%.

Motivated, mentored and coached five subordinates with Diplomas to attain B.Tech level. Name and address of employer Johnson Matthey Pvt Ltd Company, Corner Henderson and Premier Roads, Germiston South Extension 7, Gauteng, South Africa

Type of business or sector

Reason for leaving

Manufacturing - Catalytic converters for Motor Industry Career growth and prospects of broader application of acquired knowledge Period 02/2006 to 11/2007

Occupation or position held Research Masters in Chemical Engineering – Full time collaborative research studies. Main activities and responsibilities Collaborative research at North West – Potchefstroom University with Eskom

Research on coal combustion flue gas cleaning and sulphur capture using South Africa dolomite, limestone and inherent in-situ sulphur capture of South African based coal ash

Simulating a pilot fluidised bed coal combustor on thermogravimetric analyser, both atmospheric and fluidised

Physical and chemical characterisation of dolomite, limestone, coal ash

Reactivity testing and reactivity kinetics modelling Achievements Troubleshooting use of thermogravimetric analyser at pressures up to 20 bar with corrosive gases making the sulphation research possible

Completed an intensive research Masters in 20 months adding to flue gas cleaning knowledge. Passed Research Methodology with a distinction

Name and address of employer North West University, Potchefstroom Campus, Hoffman Street, Potchefstroom, South Africa Type of business or sector

Reason for leaving

Academic - Research in thermal based power sector

Completion of collaborative research project and study Period 07/2004 to 01/2006

Occupation or position held Senior Process Engineer/ Production Superintendent (15 subordinates) Main activities and responsibilities Managing all chemical engineering aspects of the manufacturing process

Production management and process control

Production process manufacturing cost control

Production and raw materials planning

Process optimisation and management

New product introduction into manufacturing process

Championing continuous process improvement initiatives

Project management; Quality control

Environmental and safety management

Technology management and process research

5

Achievements Introduced use of wood waste from sawmills as raw material in board making, achieving 10% cost reduction on roundwood.

Production process efficiency improvement from 80% to +90% by optimising unit operations. Name and address of employer PG Zimbabwe Limited, Mutare, Zimbabwe Type of business or sector

Reason for leaving

Manufacturing - Pulp Hardboard and Bison-board (urea-formaldehyde board) To pursue a collaborative research study and Masters in Chemical Engineering Period 08/2002 to 06/2004

Occupation or position held Process Engineer

Main activities and responsibilities Process management and process optimisation

Raw material planning, control and mass balances

Projects control

Aligning process with safety, quality and environmental management systems

Updating of process operation procedures and resultant training

Process utilities optimisation

Achievements Achieved a sustainable 25% reduction in particleboard manufacturing cost through optimisation of urea formaldehyde plant operation and blending with cheaper para-formaldehyde. Name and address of employer PG Zimbabwe Limited, Mutare, Zimbabwe Type of business or sector

Manufacturing – Pulp Hardboard and Bison-board (urea-formaldehyde board) Period 06/2000 to 08/2001

Occupation or position held Undergraduate Process Engineer Main activities and responsibilities Daily refinery mass balances

Matte receiving and grading from the concentrator;

Material planning batching for the process

Representative sampling of all critical process units

Management of cobalt removal plant from nickel leachate

Targeted training and operation of filtration plant, Leaching plant, milling, cementation, thickeners, pelletisers, smelter and plating tankhouses. Name and address of employer Rio Tinto Zimbabwe Ltd, Eiffel Flats, Zimbabwe Type of business or sector

Mining - Integrated copper-nickel refinery using Autokumpu Process Education and training

Period 02/2010 to 11/2012

Title of qualification awarded Masters in Business Administration Principal subjects/Occupational skills

covered

Financial reporting; Organisational behaviour; Business law and ethics; Managerial statistics; Managerial economics; Information management; Managerial accounting; Marketing management; Operations management; Entrepreneurship; Financial management; Change management; Research methodology; Strategic formulation and implementation; Strategic management application

Mini-dissertation – work related attitudes and outcomes in a manufacturing concern Name and type of organisation

providing education and training

North West University, Potchefstroom Campus, Faculty of Economic and Management Sciences, Potchefstroom Business School

Period 02/2006 to 11/2007

Title of qualification awarded Master of Science In Chemical Engineering Principal subjects/Occupational skills

covered

Sulphur dioxide capture under fluidised bed coal combustion conditions; Coal, limestone and dolomite characterisation; Experimental design and reactivity tests; Reactivity and kinetic modelling Name and type of organisation

providing education and training

North West University, Potchefstroom Campus, School of Chemical and Minerals Engineering and Eskom Technical Services Centre

6

Period 08/1997 to 05/2002

Title of qualification awarded Bachelor of Engineering in Chemical Engineering Principal subjects/Occupational skills

covered

Core Chemical Engineering studies; Reaction Engineering; Unit Operations; Chemical Engineering Thermodynamics; Process Engineering; Operations Management; Design; Research and Development Projects; Environmental Process Engineering; Advanced Minerals Processing

(Extractive Metallurgy); Engineering Economics and Project Appraisals, Process Feasibility Studies. Name and type of organisation

providing education and training

National University of Science and Technology - Bulawayo, Zimbabwe Period 2001

Title of qualification awarded Certificate in Selling and Sales Management Principal subjects/Occupational skills

covered

Principles of selling and sales management; Case studies in selling; product development; Market research and product feasibility studies.

Name and type of organisation

providing education and training

London Chamber of Commerce and Industry, International vocational awarding board Period 2004

Title of qualification awarded ISO 9001:2000 Quality Management Systems Internal Auditing Principal subjects/Occupational skills

covered

ISO 9001:2000 Quality Management Systems Internal Auditing. Development of Standard operating procedures.

Name and type of organisation

providing education and training

Nebuer Management Consultant (Pvt) Ltd – Registered Management Consultant Company in Zimbabwe

Period 2004

Title of qualification awarded Environmental Management and Cleaner Production Systems and ISO 14001: Environmental Management Systems

Principal subjects/Occupational skills

covered

Environmental Management and Cleaner Production Systems, Designing for waste minimisation and waste elimination, Importance of use of environmental management systems, International sustainability drive.

Name and type of organisation

providing education and training

Centre for Continuing Engineering Education, University of Zimbabwe Period 2004

Title of qualification awarded Management Development Program Principal subjects/Occupational skills

covered

Principles of people management; First line management; Team management; performance appraisal systems; Administration; Cost analysis: cost management; Project management. Name and type of organisation

providing education and training

Zimbabwe Institute of Management

Period 2009, 2012, 2015

Title of qualification awarded Fire fighting

Principal subjects/Occupational skills

covered

Fire engineering and safety training; firefighting principle and practical; designing for fire safety Name and type of organisation

providing education and training

Fire Consult (Pvt) Ltd, Registered and approved fire engineering company in South Africa Period 2014, 2015, 2018

Title of qualification awarded World Class Manufacturing (WCM) systems and principles Principal subjects/Occupational skills

covered

Hands on training on application of WCM systems in processes as a driver for sustainability Name and type of organisation

providing education and training

Saint Gobain, Productivity SA

Professional Membership Associate Member of SAIChE/IChemE membership Number 008073 7

Skills and competences

Mother tongue(s) Shona, English

Other language(s)

Self-assessment Understanding Speaking Writing

European level Listening Reading Spoken interaction Spoken production English Very good Very good Very good Very good Excellent Common European Framework of Reference (CEF) level Interpersonal skills and competences Strong teamwork skills Strong interpersonal skills

Networking with trade unions, key industry players and government departments Good diversity management and ability to interact with all cultures Good team player and ability to motivate subordinates Good and objective negotiator

Respect for people and their values without compromising ability to objectively interact Very good social skills from societal upbringing and education systems, previous jobs, research collaboration, interaction with various industry stakeholders Managerial competences Team leadership and people development Results focus and effectiveness in driving business objectives Promoting effective customer focus and developing similar to team Identifying performance gaps and taking initiatives Articulation of business vision and strategy

Promotion of innovation and continuous improvement and operational excellence Change management

Stakeholder management

Financial management

Customer relations management

Organisational skills and competences Time conscious and adherence to deadlines Change management skills

Systematic in planning

Excellent organisational skills from the level and seniority of employment positions I have held, project type work, working with various resources to achieve organisational goals and working on deadlines, objective oriented responsibilities.

Technical skills and competences Versatile engineering and technical skills Good business acumen

Very technical, in all positions held have also acquired high competence in related through teamwork and interaction with mechanical, electrical and control engineers Computer skills and competences Competent in use of MS Office packages, Ms Word, Ms Excel, Ms PowerPoint Visio

Conversant with use of ERP programmes like SAP;

Internet

Basic knowledge in using of CAD

IT security and risk management

Other skills and competences WCM, research, business management Driving licence(s) Code 08 driver’s licence for private vehicles 8

References Mr Donagh Nolan, GM Operations, Saint Gobain Gyproc and Isover, South Africa, Email: adcnnr@r.postjobfree.com

Cell: +27-76-814-****

Professor R.C Everson, Chemical Engineering Dep., North West University –Potchefstroom P Bag X6001, Potchefstroom, 2520, South Africa, Phone +27-18-299-**** Email: adcnnr@r.postjobfree.com

Ms Phumeza Nobhongoza, Training Advisor, NBC – Productivity Institute, 350 Victoria Road, Industria House, Salter River, 7925, Cape Town, Cell: +27-78-606-****

Email: adcnnr@r.postjobfree.com

Mr Yaw Asamoah-Bekoe – Technical/Process Engineering Manager Johnson Matthey Ltd, P O Box X028 Wadeville, Gauteng, 1422, South Africa Cell: +27-82-943-****

Email: adcnnr@r.postjobfree.com

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