Boy - General Manager - Louis Trichardt, South Africa

Kisbey Boy

Louis Trichardt, South Africa


General Manager


Specialize in the FMCG environment with strong mechanical and production background. B-Tech graduate.

Work History

General Manager

Rhodes Food Group

Duties and Responsibilities:
• Draft full budget
• Execute all Capex items and oversee all projects
• Quarter financial feedback to board of Directors and major stakeholders
• Daily stats and review corrective actions
• Broke down complete unit and rebuilt to world class manufacturing facility in 3 years.
• 7 Managers report to me, Technical Manager, Maintenance Manager, Production Manager X2, Admin Manager, Distribution Manager, Labelling Manager, Agricultural Manager and HR Manager.
• Line Manning of 550 people seasonal and 140 non seasonal permanent employees.
• Site 40 000m2 which 12 000m2 under roof
• Comply with all SHE Audits, HACCP and ISO 22 000
• Conduct all disciplinary hearing including CCMA cases.
• Implemented OEE and visual performance management
• Install highly technical advance automated equipment and maintaining.
• Implemented lean Manufacturing and six Sigma.
• Managing monthly stock takes
• Managing 140 000 tons of raw materials, dry beans, peas, butter beans, tomatoes, sweetcorn, sugar and many more. Working capital R70 million per month.
• Manage all transport to and from unit to customers.
• Production scheduling according to forecast
• Implemented MRP system
• Test raw Materials for heavy metals and infestation
• Fumigation of all dry raw materials monthly
• Involved and formalising all new product development
• Managing 2X 20 ton boilers and all water treatment including dispatch into effluent. pH and TDS
• All financial indicators such as BOM and daily stats and accounting.
• Chairman of EE forum and skills development plans.
• All wage negotiations with trade Union ( FAWU)
• All medical and health screening
• All WCA incidents
• Attend and drive Health & Safety committees.
• Clear understanding and experience in workplace improvements such as 20 KEYS.

was headhunted by Rhodes as General Manager


Unit Manager

Tiger Brands

January 2006 - August 2006

Duties and Responsibilities:
• Minimise changeovers, setup and start up times
• Line Balancing and Stock control
• Planning and control of raw materials per line
• Optimization of equipment for better OEE
• Feasibility studies to improve process and layout
• Handling all suppliers and customer complains
• Creating jig compatibility studies to improve efficiencies
• Run and conduct Quality circle and TPS
• Train operators on new work instructions
• Implementing of all packaging work instructions per supplier
• Implementing Quality Control to reduce scrap rates and other quality costs
• Identify, plan & implement production requirements in support of OPR/SDR targets for New Models / Facelifts / ECI's introduction (i.e. Layouts, Process Flow, Dunnage, BOM's, Consumables, Training, Quality Network, Tooling, etc)
• Participation in Projects, Development Work and Kaizen Activities
• Continuous improvement activities on current processes to reduce operating costs
• Establishing Tooling and Capital budget funding requirements
• Equipment & Tooling identification, procurement and commissioning
• Costing and Feasibility studies
• Handling and controlling all farmer contracts
• Scheduling of incoming raw Materials
• Draft budget of R60 mil and managing thereof.
• Achieved 99% on SHE audit
• Production variance 12 Mil positive for the year on yield raw materials.
• Rated the best 20 KEY continuous Improvement within the whole Tiger Brands group.
• Managing 160 000 tons of raw materials(Fresh Tomatoes)
• Was promoted to a Canning Unit in Duiwelskloof as Unit Manager

Unit Manager

Tiger Brands

Duties and Responsibilities:
• To be the custodian of the Mission Directed Work Teams (MDW) in our stream:
• Conduct 5s and general audits
• Conduct and monitor the implementation of suggestions (Kaizen).
• Continuously update the stream's layout and demarcations.
• Train Operators on MDW modules.
• Make graphs for the OEE, Uptime, Throughput, Changeovers and Losses.
• Present OEE reports on every Tuesday meeting.
• Conduct monthly supplier and customer audits and report to the Stream leader.
• Conduct machine time studies and compare them to standards.
• Analyse CNC4 daily reports - make a comparison between the case and the actual performance of the machine.
• Analyse all production control reports and make recommendations if necessary.
• Continuous improvement of the Speed and Yield.
• Analysis and reduction of the stream losses.
• Visual management.
• Capacity management.
• Conducting packaging safety audits.
• Visit Customers to solve packaging problems.
• Develop packaging instructions for new part numbers.
• Modify packaging in cases of glasses breaking in-transit.
• Conducting ergonomic studies in the packaging department.
• Develop new packaging and conduct viability studies.
• Packaging trial runs.
• Stock take and cycle counts
• All CAR Reports
• All CAPEX implementation and drafting
• Inline production
• Water purification
• HACCP AND GMP compliance
• SHE Audits
• SAFSIS Audits (Pick and Pay)
• Monthly report on financial indicators to board of executives.
• Monitor the packaging supply chain.
• Continuous improvement projects:
• Renovation of the Tool Store
• Optimization of Set Up / Changeover times.

Operations Manager

Tiger Brands

January 2003 - December 2005

Duties and Responsibilities:
Principle Outputs
• Implemented Production Schedules
• Implemented Continuous Improvement Initiatives
• Managed Line Effectiveness and Efficiency
• Managed Budget
• Reported information
• Managed routines
• Monitored Quality
• Complied to TCCQS, GMP
• Complied to Health, Safety and Environmental Legislation
• Selected Staff and Organize Production Teams
• Maintained employee relations
• Managed Team Performance
• Developed people
• Industrial Relations-(discipline on people, handling grievances)
• Operations of 2 plants baby cereal and jarred baby food
• Production and Maintenance managers reported to me
• Extremely clean and sensitive products to manage
• GMP Principles applied
• Housekeeping
• Capacity, availability and Efficiency of both plants
• HACCP Implementation and Maintaining certification
• FDA Audits and export into USA
• Training of all staff
• Major project installation new drum drier, travelled abroad to Japan and Netherlands to secure project and installation.
• Daily stats
Promoted to unit Manager Musina Tomato Paste Unit

Manufacturing Production Manager/Operations

Tiger Brands

From January 1996

Duties and Responsibilities:
• Responsible for all production and Maintenance objectives
• Conduct major projects including Greenfields new plant, fully automated inline
• Formulating specifications on all consumables with external suppliers
• Managing the site to ensure all Safety Compliance
• Develop all Issue Base Risks for the Unit
• Draw up Capacity from Manpower to Efficiencies
• Recruitment of new technical people
• Assist Human resource to design job specifications
• Install an OEE online live short interval measurement.
• Wrote all SOP's for equipment operation cleaning and maintaining and training of 140 shop floor staff.
• Run and manage the launch of the new product
• Management of Departmental resources including Maintenance budget, Human resources, Raw materials and consumables
• Drive Line Performance to the required OEE and Line Utilization
• Handle Disciplinary hearings and grievances
• Drive Optimization on machine and raw materials usages
• Strategic Planning during peak Season

Packaging Fitter/Superintendent


From January 1988

Duties and Responsibilities:
1. In my capacity this include managing machinery that runs a production line, This involves understanding machine designs from manufactures:
• writing up proper work instructions, change over procedures,
• training and assessment on operators, recruiting the right skills,
• Following a structured maintenance plan to maintain machine conditions
• Monitoring of schedules
• Outline proper Risk assessment of equipment
• Conducts audits on equipment
• Maintain and Manage Quality
• Ensure machines are running at the required speed as to the design capacity
• Ensure efficiencies/targets are achieved
• Manage plant shutdowns and start-up
• Run continuous improvement projects through Total Productive Maintenance and World Class Maintenance
• Been awarded best performer for 8 years on high speed packaging equipment.
2. Liaise with customers and build customer relations.
• As a Production manager one plays a pivotal role in terms of relations as I am linked to the Quality Manager- my role to ensure all products produced meet a set quality specification,
• Warehouse Manager- I need to ensure that products that are planned are produced at the set period of time without spoilage and expiry dates
• Customers- understanding consumers outside know what they need and when, normally I do trade visit with Sales and Marketing.
• Suppliers on raw materials - run monthly meetings to review any contracts or review if they still meeting the agreed specifications. At times negotiate price cuts
• Maintenance of product quality.
• Supervise and Manage staff at the plant.
• Prepare budget.
• Set up shift patterns as to product demands
• Conduct industrial relations-i.e. disciplinary hearings, coaching and counselling
• Ensure employee safety clothing is provided
• Conduct recruitments and hiring through interviews
• Manage time and attendance.
• Run meetings with shop stewards monthly.
• Prepare training and development of employees
• Prepare succession roles...

Apprentice Diesel Mechanic

TSB Sugar Association

From January 1983

Duties and Responsibilities:

Qualifications & Certifications

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