Process Engineering Project Management

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Steady Mukondiwa (MBA, MSc (ChemEng), BEng (Chem), AMIChemE)

Personal Information

Contact number: 083-***-****

E-mail address: ***********@*****.**.**

Location: Boksburg West ext. 1, 1459, Gauteng

Date of birth: 1976/07/09

Languages: English, Shona, Ndebele, Zulu

Gender: Black male

License: Code 08 (EB)

Core Competencies

- General Management - Reporting to Board - Policy Deployment

- Stakeholder Relations - Customer Relations Management - Operational Excellence

- Financial Management - Continuous Improvement - Change Management

- Leadership Coaching - Operations Management - Strategy Formulation & Implementation

- Process Design - Innovation Management - Business Analysis and Data Analytics

- Research Management - Chemical Process Engineering - Quality Assurance

- Project Management - Technology Road Mapping - Skills Development Management

- Business Sustainability - Bargaining Council Operations - Business Consulting

- Business Turnaround - Benchmarking - Entrepreneurial Development Executive Summary

A versatile engineering and management professional with 24 years leadership experience in the manufacturing sector implementing innovative operational strategies and systems. Stakeholder management experience engaging business, trade unions, academia, government departments, local and international support organisations focusing on business growth initiatives. Manufacturing operations experience in glass-wool insulation, catalytic convertors, minerals processing and refining, wood-based fibre, clothing and textile manufacturing sectors. Extensive experience in functional leadership roles in process engineering, product development, business integration, business optimisation/sustainability, value chain and supply chain strategy focusing on optimising productivity and competitiveness. Application knowledge of human machine interfaces in automated/robotic processes, artificial intelligence and related technology optimisation. Deployment experience of policies and procedures in manufacturing excellence, health and safety, business continuity, plant design and operations, human capital optimisation. Implementation experience of integrated management systems ISO9001, ISO14001, ISO18001 and ISO50001. Leadership impact 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. Passionate skills development advocate for individuals and teams, harnessing collective efficiency optimising organisational capacity. I am a balanced life family man, a self-discovered active road running enthusiast applying the acquired experience and leadership knowledge in social life as a member of Church Council subcommittee for finance, strategy, and ethics. Work experience

Period 04/2025 to (Current)

Occupation or position held Director

Name of employer Holistic Strategic Business Management Consulting Services (HSBMCS) Services and Achievements • • Strategy consulting

• • Project management, project scoping and business case development

• • Productivity and operational excellence support services

• • Process engineering, data science and digital strategy

• • Leadership coaching, mentorship and training services

• • Business control, finance & auditing services

• • Community & social development services

• • Maintenance management services

• • Factory design and set up support services

• • Business turnaround solutions

• • Business and technology optimisation

• • Business proposal development

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Period

04/2016 to 03/2025 (Renewable Contract Position)

Occupation or position held Director – Productivity and Training (+100 industry service providers, consultants & researchers working with +650 factories)

Name of employer National Bargaining Council for Clothing Manufacturing Industry Responsibility and Achievements • Managing sectoral productivity and training strategies in line with sectoral and national masterplan policies ensuring sound administrative, financial controls and good governance

• Coaching business leaders to implement and attain economical productivity, competitiveness and business sustainability in their entities

• Identifying business support intervention collaborations to address sectoral challenges, establishing partnerships (e.g., with Tertiary institutions, FP&M SETA, W&R SETA, Proudly SA, Productivity SA, and Provincial Governments) to drive sector turnaround and recovery interventions implementable at both individual and sectoral level

• Drafting proposals and business cases/motivation for funding to support enhanced skills development programmes focusing on technology relevant skills required to grow industry in line with industry Masterplan and sector Skills Accords

• Conducting industrywide technology and manufacturing systems diagnosis and benchmark on technology, productivity and skills to inform sector technology strategy roadmap integrating relevant technology and inform optimised training models

• Implementing a CTFL value chain intervention on economic recovery and reconstruction programme (ERRP) harnessing skills in high demand in unemployed learners and students to support and catalyse sector productivity

• Promoting world class manufacturing (WCM) model implementation in collaboration with various services providers to drive business level productivity

• Establishing collaborative technical partnership with ILO to implement the flagship SCORE (sustaining competitive and responsible enterprises) and Productivity Ecosystem programmes in the clothing and textile manufacturing sector and securing funding for rollout in sectoral factories

• Driving implementation of relevant sector developmental agreements such as implementation of skills-based job grading and technology road mapping studies

• Successfully project managing convening of a value chain conference of 500 key stakeholders from the Clothing, Textile, Footwear and Leather (CTFL) value chain to strategize on leveraging value chain opportunities

• Successfully facilitating and project managing the 1st ever NBC facilitated 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”

Period 10/2012 to 03/2016

Occupation or position held Senior Process Engineer/Process Engineering Manager – Process Department Head (four direct subordinates + 80 factory process operation employees) Name of employer

Main activities and responsibilities

Saint-Gobain Isover, Springs, Gauteng, South Africa

• Managing the Process Engineering Department and supporting the glass wool 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

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• 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.

• 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 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.

Reason for leaving

Taking a developmental, strategy delivery role for broader hands-on knowledge application and career growth to broaden span of control and engagement within a different sphere industry.

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Period 03/2008 to 10/2012

Occupation or position held Principal Process Engineer (five direct subordinates and 40 factory operations employees) Name and address of employer Johnson Matthey Pvt Ltd Company, Germiston South Extension 7, Gauteng, South Africa Mai Activities Responsibilities and

Achievements

• All process engineering and process management functions similar to above role at Saint-Gobain

• 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.

Reason for leaving Increased span of control, career growth and broader application of acquired knowledge Period 02/2006 to 11/2007

Occupation or position held

Name and address of employer

Research Master of Science in Chemical Engineering collaborative research studies – full time.

North West University, Potchefstroom, South Africa 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

Reason for leaving Completion of collaborative research project and study and going back to corporate roles Period 07/2004 to 01/2006

Occupation or position held

Name and address of employer

Senior Process Engineer/ Production Superintendent (15 subordinates) PG Zimbabwe Limited, Mutare, Zimbabwe

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

Achievements

Reason for leaving

• 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 and standardising operating procedures. To pursue a collaborative research study and Masters in Chemical Engineering 5

Period 08/2002 to 06/2004

Occupation or position held

Name and address of employer

Process Engineer

PG Zimbabwe Limited, Mutare, Zimbabwe

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 paraformaldehyde.

Period 06/2000 to 08/2001

Occupation or position held

Name and address of employer

Undergraduate Process Engineer

Rio Tinto Zimbabwe Ltd, Eiffel Flats, Zimbabwe

Main activities and responsibilities • Daily refinery mass balances

• Matte receiving and grading from the concentrator

• Material planning and 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 tank-houses. Education and training

Core Qualifications

Institution Qualification Year

UCT Executive and Management Coaching 2022

Northwest University Master in Business Administration 2012 Northwest University Master of Science in Chemical Engineering 2007 NUST, Zimbabwe Bachelor of Engineering in Chemical Engineering 2002 Additional Training

• London Chamber of Commerce - Certificate in Selling and Sales Management, 2001

• Nebuer Management Consultant (Pvt) Ltd - ISO 9001:2000 Quality Management Systems Internal Auditing, 2004

• University of Zimbabwe - Environmental Management and Cleaner Production Systems and ISO 14001: EMS, 2004

• Zimbabwe Institute of Management, Management Development Program, 2004.

• Fire Consult (Pvt) Ltd, Registered, Firefighting, 2009, 2012, 2015.

• Saint-Gobain, Productivity SA, World Class Manufacturing (WCM) systems and principles, 2014, 2015, 2018. Professional Membership

Skills and Competences

Associate Member of IChemE membership Number 008073 Languages Fluent in English and Shona and can communicate in Ndebele/Zulu Interpersonal skills and competences Strong interpersonal and teamwork skills Stakeholder engagement and management

Working with multi-stakeholders, trade unions, key industry players, government departments and international development agencies Diversity management and ability to interact with all cultures Effective team player with ability to motivate subordinates and developing star performers

Effective and objective negotiator

Effective communication skills

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Managerial competences Strategy formulation, implementation, and articulation of business vision Formulating and executing manufacturing turnaround strategies Executive and management coaching

Governance, ethics, and development of organisational policies/procedures Operations management

Team leadership and skills development

Productivity enhancement through lean and world class manufacturing systems Promoting effective customer focus and developing similar competences to team Identifying performance gaps and taking initiatives Management of innovation, continuous improvement, and operational excellence Change 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

Chemical process engineering

Process design

Process integration

Business and process analysis

Quality assurance

Research and innovation management

Versatile engineering and technical skills

Process improvement, continuous improvement, and lean world class manufacturing 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 enterprise resource planning (ERP) programmes like SAP Internet

Basic knowledge in using of CAD

IT security and risk management

References available on request

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