Manfred T. Mushininga

Laboratory & Process Engineer

M. Eng. Industrial Eng. (MSOM), B. Eng. (Hons) Chemical Engineering, Cand. Eng. (ECSA), AMIChemE

I am an industrious and results-orientated Chemical Engineer with more than 12 years’ experience in heavy industry operations, projects, laboratory work (R & D) and optimisation. Having worked in various manufacturing environments (Iron and Steel, Cement, Fertiliser, Oil and Gas, refinery), I am adept at managing multi-million-dollar projects, designing various equipment and vessels, while keeping the project within the given budget. I am highly skilled in both Chemical Process Engineering and Industrial Process Engineering.

I offer well-rounded overall abilities and skillsets, including resource management and analytical abilities, of which my specific areas of excellence are:

Project management of Brownfield and Greenfield projects with the ability to work on both short and long-term projects with estimated values of over USD 10 million.

Production capacity de-bottlenecking, energy optimisation and process variation optimisation

Design and sizing of heat exchangers, pumps, valves, absorption columns, stripping columns, distillation columns, ion exchangers, cooling towers, decanters etc. and providing guidance for their optimal performance in various operational conditions.

Ability to envision process / project improvements through research and to communicate these ideas to Engineers, top management, designers and subordinates with positive results.

Using various skills including CHEMCAD, Aspen HYSYS, MATLAB, Arena with Simulink, CAD/CAM, MS Projects and MS Visio to adequately design and factor in parameters needed as well as to manage project costs and the progress of implementation.

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PERSONAL DETAILS

Gender: Male

ID: 820**********

Ethnicity: Black

Home Address: Lombardy East, Gauteng

Date of Birth: 8 August 1982

Notice: 1 Calendar month

Recent package: R41 700 p.m. + company car + fuel card + annual bonus

Expected Package: Negotiable

Reason for looking: My current job is part time and more industrial engineering oriented and I am looking for a challenging longer term Chemical engineering position

…Continues from page 1

Review plans of products, taking into account factors such as strength, weight, and cost in order to submit material selection recommendations while ensuring achievement of design objectives. Design and auditing of PID’s, PFD’s and material balances.

My career to date include:

5+ years in a consulting company with its focus in personnel development and organisational productivity improvement.

7+ years in an integrated organisation which produced and refined Steel, Iron, Coke, Coke oven gas and benzole crude oil.

7 months at a fertiliser company which produced ammonium nitrate fertilizer and various other compound fertilisers as ordered by customers.

2 years at a cement manufacturing company which had its own preheater kiln

I have developed myself to be a significant contributor to the overall strategic goals through consistent application of chemical engineering principles to minimise production cost up to 15% as well as growing the customer base by 5% through availing my expertise to potential clients. I am a seasoned Project Process Engineer having managed various turnkey and capital projects to their conclusion and within given time frames. Based on my experience, I am confident of adequately fulfilling the expectations of this position and of being able to add significant value to the team.

QUALIFICATIONS

M. Eng. Industrial and Manufacturing Engineering: Manufacturing Systems and Operations Management

National University of Science and Technology

2014

B. Eng (Honours) Chemical Engineering

(SAQA accredited as equivalent to B Eng. Chemical)

National University of Science and Technology

2006

FURTHER TRAINING / CERTIFICATIONS

Risk Assessment – 2011

Strategic Management – 2010

Refractory Management and Installation – 2009

Destructive and Non-destructive Metallurgical Tests – 2009

Management Skills – 2009

Project Portfolio Management – 2008

Integrated Management Systems (ISO 9001, ISO 14001 and OHSAS 18001) – 2007

Industrial Relations – 2007

Root Cause Analysis Courses – 2005

MS Projects – 2005

MEMBERSHIPS / PROFESSIONAL AFFILIATIONS

Engineering Council of South Africa – Candidate Engineer (No. 201-***-****)

Institute of Chemical Engineers (UK) – Associate member (No. 99949332)

South African Institute of Chemical Engineers – Graduate member (No. 006345)

Services SETA - Assessor and Moderator (MMUS636462144)

PUBLICATIONS

S. Mhlanga, M.T. Mushininga, C.T. Mutopa

“Analysis of supply chain as an effective manufacturing strategy tool for a Textile Manufacturing firm”

SAIIE26 proceedings, 14th – 16th July 2014

CONFERENCES

SAIIE26 proceedings, 14th – 16th July 2014, Magaliesburg, South Africa © 2014 SAIIE

(Presented the above paper)

COMPUTER LITERACY

Pascal

Q-basic

Command prompt

AutoCAD

Autolisp

Visual Basic

Excel/VBA

LINGO (Computing and Solving Linear Programming, Dynamic Programming, Transportation Problems, Assignment Problems, Network and Critical Analysis, Goal Programming)

LINDO

TORA

Smart-Draw

Prokon

MS-Project

E-draw

Arena Simulation with in-built Siman v language

MATLAB

Simulation X

Microsoft Visio

C-programming

Pro II

Aspen Hysys

Solidworks

Batch Column

CHEMCAD

SCADA

PLC

SAP

ERP

Microsoft software packages

EMPLOYMENT HISTORY

Company Name: EOH (NEXTEC – Sabela)

Job Title: Engineering Consultant – Process Optimisation

Dates: January 2015 – Current

POSITION OVERVIEW

Manufacturing consulting role in which he takes part in bench motion studies and upgrade the efficiency of operations through identifying gaps in the system and providing timeous solutions.

RESPONSIBILITIES

Project Management

Managing projects from inception to completion – providing timeous reports to stakeholders

Monitor and track costs to minimise overall expenditure

Liaise with different suppliers to optimise delivery and quality

Customer Service and Marketing

Liaise with the clients at all times to get quality tailored delivery to meet customer specifications

Providing a forum which allows for engagement of clients and to resolve any conflicts

Provide technical support to other workers for ease of engagement with various stakeholders

Assessments and Evaluations

Conduct all required assessments of learners work and prepare all continuous assessment examination to meet the required standards for SETA’s

Produce reports and analysis to track client progress during different forums

Training and Skills Development

Maintain appropriate Continuing Professional Development through attending training events as identified by the supervisor – to ensure the highest standard of quality in outputs

Transference of skills and knowledge to other team members through workplace interactions and staff development activities

Network with colleagues to promote best practice in knowledge delivery

Mentor and prepare clients for smooth integration into the industry

SELECTED ACHIEVEMENTS

Awarded the Most Innovative Employee Award for 2018 for advancing company goals through consistent application of transparent and innovative solutions to problems, and bringing timeous resolutions to bottlenecks in projects

Improved the bench motion activities on the shop floor by performing an optimisation of the process flow which increased the productivity by 15%

Increased the profitability of each batch run in production runs by more than 10% through performing lean manufacturing audits on sections

Designed and modified pumping system so as to increase the efficiency and productivity of the process plants by more than 7%

Trained and guided process operators in the use of quality tools to identify process bottlenecks and deal with root causes in plant non-conformances – this increased plant availability by 5%

Increased the retention rate of clients by 15% through developing solid interpersonal relationships and resolving arising conflicts timeously

Performed heat exchanger calculations so as to optimise the online operations in the plant and help inform management in making conclusive decisions – this improved productivity by 8%

Performed energy and material balances to identify areas in which energy might be lost and implemented several control strategies to limit this and keep the energy in the system.

Performed periodic process audits which included HAZOP analysis as well as risk assessment analysis to identify areas which may need attention. These helped identify 70% of potential hazards in the plant.

Performed timeous process audits especially in the preheater section to verify results been shown by the SCADA system whilst checking for any build-ups and any gadgets which might be faulty so as to keep the plant in safety integrity. It helped identify 40% of the faults in the system.

Improved the company’s revenue through attracting outside markets and allowing them to expand into different areas.

Company Name: ZISCO Iron and Steel Company

Job Title: Process and Laboratory Engineer

Dates: 16 July 2007 – 17 September 2014

RESPONSIBILITIES

Cost Analysis and Evaluation

Conduct economic studies and cost analysis of different processing systems of the gas & chemical plants and associated pipeline

Originate and carry out engineering studies to determine potential problems and remedies to existing problems, resolve complex technical problems, increase revenue, optimise processes

Technical Troubleshooting and Analysis

Production capacity de-bottlenecking, energy optimisation experiments and process variation optimisation

Evaluate and introduce best practices and new technologies to help organisation achieve best-in-class positions in the oil / gas industry through extensive research and pilot studies

Perform multi-phase steady state and dynamic flow assurance studies as well as conducting pipe surge analysis (PIPESIM, OLGA)

Management and Supervision

Managed over 150 personnel with 7 direct reports and 8 indirect reports

Identified and recommended personnel for training in different aspects to increase their skillsets and enhance process knowledge

Performed the full Human Resource function which included hiring, training and disciplinary duties

Health and Safety

Fostering a strong environmental, Health and Safety culture within and across teams responsible for Option Development, PID development, coarse HAZOP studies, Equipment Specification and Selection, Operating Philosophies and Procedures, Cost Analysis and Value Engineering, sourcing and purchasing recommendations

Quality Assurance

Managed advanced product quality planning involvement (specifically FMEA’s) to ensure considerations were given to the effects / impacts of process changes to product quality by validation that no harm was done

Performed timeous process audits and quality checks to keep the product within specification while producing guidelines for the use of statistical process controls as a monitoring tool.

System Maintenance and Analysis

Managed support in areas of production enhancement, availability and reliability improvement, equipment troubleshooting, performance monitoring, correct operations procedures and manuals

Used captured data to identify machinery and unit operations with consistent failure rates to perform full diagnostics using SAP software

Modelling and Analytical

Used process simulation tools (Pro II, Aspen Plus, AFT Fathom) for problem solving

Performed thermal and material modelling of different unit operations to develop viable system operational plans and minimise losses

Project Management

Planned and managed Brownfield and Greenfield projects up to USD 10 million to completion and within given timeframes

Used MS Projects to track progress and maintain cost analyses

Designed and implemented products for enduring energy cost saving initiatives, process improvement, modifications and new installations

Prepared tender documents / scope of work as a basis for service provision as well as evaluated subsequent tender submissions and provided sales support in respect of client enquiries to meet the company’s business plan and objectives

Managed advanced product quality planning involvement (specifically FMEA’s) in order to ensure considerations were given to the effects / impacts of process changes to product quality by validation that no harm was done

Determined project specifications by studying product design, customer requirements and performance standards; completed technical studies; prepared cost estimates; liaised with different field experts to carry out this function

SELECTED ACHIEVEMENTS

Designed an effective tar firing unit to heat up the Coke Ovens batteries using extensive R & D (Integrated Steel Plant - 2012) – 10% savings on the project costs.

Improved the electrostatic precipitator efficiency by 7% by modelling the effect of misaligned rods and impact on the downstream operations and reduced tar blockages by 15%

Designed primary cooler modified capacity to carter for expansion in the productivity levels whilst modelling the operational capability of the same focusing on the effect the deterministic settling of tar particles has on the effectiveness of the same.

Reduced slippage in the absorption columns by approximately 12% by modelling the atomisation of oil by the sprays and the effect of a droplet on absorption.

Utilisation of the Failure Mode and Effect Analysis (FMEA) for the optimisation of boiler operations (Thermal Power plant - 2012): Decreased operating costs by at least 15%.

Successfully programmed post and pre operating data inputs using excel for easy access and quick analysis using statistical process controls increasing effectiveness and efficiency (7%).

Designed and modelled the heat exchanger operations in the gas refining plant to improve performance (by 10%) and increase their capacity (by 15%).

Saved 25% of the Coke Ovens refurbishment costs by utilising in house resources for scope of work, material specifications and implementation. (2010 – 2012).

Designed a sprinkling system to suppress dust as well as upgraded the dust suction system to limit the amount of dust in the coal plant. This was a safety project which resulted in the limitation of particulate dust which was causing blockages in the drainage system and the pre-treatment plant for water.

Redesigned the settling ponds mechanism which reduced spillages in the plant and increased recycling of spilled material by 15%. He initiated the project which resulted in the improvement of the pre-treatment ponds for the effluent treatment plant.

Redesigned and built a modified drainage system in the coal plant to improve the water drainage form different areas. This improved the coal plant's utilization by 5% and reduced the flooding in the plant by 20%

Trained 40% of the plant personnel in different shifts fire-fighting techniques so as to keep them alert to the risk of fires and have adequate people skilled in putting out fires in the event that they broke out. This was part of my efforts to increase the skillset of every personnel in the plant and as such improve the gap phase between knowledge needed and the one that is available.

Performed energy and material balances to identify areas in which energy might be lost and implemented several control strategies to limit this and keep the energy in the system.

Performed periodic process audits which included HAZOP analysis as well as risk assessment analysis to identify areas which may need attention. These helped identify 70% of potential hazards in the plant.

Performed integrity test on pressure vessels as well as on pipelines whilst doing sonar detecting tests to ascertain the condition of all pipeline and vessels. It helped in budgeting for replacements and in highlighting vessels for concern which might need to be isolated. This helped identify the vessels and pipes which were due for replacement before they failed and assisted me in working out a model that could assist us in identifying the life of each of the vessels in the plant given operations remained the same.

REASON FOR LEAVING

Relocated and was looking for additional challenges where he could more fully utilise his skillset and further develop new ones.

Company Name: ZFC Fertiliser Company

Job Title: Graduate Chemical Engineer

Dates: January 2007 – July 2007

RESPONSIBILITIES

Health and Safety

Participated in HAZOP / HAZAN studies, value engineering exercises and design review

Design and Development

Process Design Development through careful selection of process technologies based on Company design guidelines and good engineering practice, providing cost-effective solutions and ensuring technical compliance with requirements

Quality and Environmental

Identification of areas for Quality and GMP improvement in the manufacturing areas, and assisting in the implementation of systems and training and monitoring of these

Evaluation of Quality Operating Reports and liaison with Production for Right First Time improvements for quality and productivity

Development and implementation of standards and practices to suit the quality, and operational requirements of the plant, including ISO 9001:2008; ISO 14001 and OSHAS 18001

Production and Cost

Improved production efficiencies and reduced operational costs

Management and Administration

Management of employees to achieve high levels of competence, retention, performance management and team work

SELECTED ACHIEVEMENTS

Optimising the boiler operations improving the coal combustion by 10%, the heat transfer by 5% and the overall steam production by 7%.

Formulating and producing fertiliser compounds as per customer requirements timeously by achieving good rapport with supporting staff and impacting adequate training to get good flexibility.

Designed and provided the guidelines for isometric system during the installation of the new nitrogen tank. The commissioning was done without any mishaps.

Performed periodic process audits which included HAZOP analysis as well as risk assessment analysis to identify areas which may need attention. These helped identify 20% of potential hazards in the plant.

Performed energy and material balances to identify areas in which energy might be lost and implemented several control strategies to limit this and keep the energy in the system.

Trained in three management systems (ISO 9001, ISO 14001 and OSHAS 18001) through which he participated in providing guidelines for the whole plant in making their tasks compliant to the systems and drive the awareness in the plant concerning the same.

Redesigned the screening section so as to limit spillage in the plant.

Performed process and safety audits to identify areas which needed attention and kept close monitoring of the measuring gauges in the plant so as to limit any unexpected accidents

REASON FOR LEAVING

Career growth as the next position offered better exposure to a wider and diverse unit operations experience

Company Name: Lafarge Cement – Manresa Works

Job Title: Intern Chemical Engineer

Dates: 17 May 2004 – 20 October 2006

RESPONSIBILITIES

Health and Safety

Participating in HAZOP / HAZAN studies, value engineering exercises & design review

Optimisation and Analysis

Loaded item masters into SAP and assisted in root cause analysis exercises

Provided specialist process engineering service in managing production processes to meet capital utilization, product availability and quality targets

Management and Administration

Contributed to production planning and the strategy to meet market and stockholding targets

Ensured that work execution was completed in accordance with company policy, procedures and work instructions

Troubleshooting and Analysis

Expert understanding of operation maintenance, production strategies and MAC system

Optimising the kiln, mills and pneumatic conveying systems efficiencies during operations by constantly reviewing PFD’s, PID’s and performance mass and energy balances

Performing process audits to optimise performance of unit operations

Research and Development

Performed pilot tests and laboratory work to improve the quality of the clinker and cement produced through introducing best mix to plant operations

Ramp simulation for modelling reliability, availability and maintainability

SELECTED ACHIEVEMENTS

Performed timeous process audits especially in the preheater section to verify results been shown by the SCADA system whilst checking for any build-ups and any gadgets which might be faulty so as to keep the plant in safety integrity. It helped identify 40% of the faults in the system.

Made ball mill process audits and inspected the media and auxiliary material therein. This helped improve the productivity by 12% and identified liners which might need replacement through and auxiliary heuristic modelling from the deterministic data he found.

Used an SAP system to identify the most common action areas were safety and breakdown incidents were occurring using reported data so as to identify areas which needed to be addressed and prevent further injuries.

Performed energy and material balances to identify areas in which energy might be lost and implemented several control strategies to limit this and keep the energy in the system.

Performed periodic process audits which included HAZOP analysis as well as risk assessment analysis to identify areas which may need attention. These helped identify 30% of potential hazards in the plant.

Improved the cement properties (strength - 5%, setting time - 2%, surface area - 7%) through running pilot test at micro-scale in a laboratory level.

Optimised the ball mills to improve the crushing efficiency and particle size distribution by carrying out modelling operations and adding charge as necessary as well as advising on the maintenance equipment affecting the same.

Improved the pre-heater section heat transfer efficiency by 7% through modelling the overall section thermodynamic operations and advising on changing capacities.

Improved the pneumatic conveying system through timeous process audits and modelling to achieve optimal results.

Improved the electrostatic precipitator efficiency by 4% through modelling of the overall operations and achieving required improvement.

Optimised the kiln operation through improving the firing sequence by measuring the grinding capability of the vertical mills and improving the compressor efficiency by 6% when firing the same. Also the refractory reduction per tonne of clinker formed was modelled and used as a means of extrapolating the need for change of the same without getting hot spots.

Modelled the rate of wear of the kiln refractory lining using probabilistic and deterministic data for use in the analysis and extrapolation of anticipated replacement.

Was awarded the most innovative production award for safety improvement ideas after designing several models to improve the safety and hazard detection in the various sections of the works.

REASON FOR LEAVING

Internship completed

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