Mocheko Caiphus Moloto

Senior Production Controller | Metallurgical & Mineral Processing
Borkum, ZA.

About

Results-driven Senior Production Controller with over 15 years of expertise in metallurgical and mineral processing, specializing in Ferrosilicon and Zinc production. Proven ability to optimize process efficiency, significantly increase production output by 20%, and reduce operational costs by repurposing by-products. Adept at leading teams, ensuring strict quality assurance, and maintaining a zero-incident safety record in complex industrial environments.

Projects

Integration of Alternative Ferrous Metal in a Ferrosilicon Production

Summary

Assessed and integrated alternative iron sources (e.g., iron scrap, snippers, coated steel) into the FeSi production process to reduce raw material costs and improve resource efficiency. Led feasibility analysis through material sampling, chemical testing, and risk evaluation to ensure compatibility with existing furnace operations. Developed safe batching, charging, and feeding procedures tailored to non-traditional material shapes and compositions. Achieved 15% raw material cost reduction through successful scrap integration. Maintained consistent product quality by implementing a new grading and inspection process. Completed project 2 weeks ahead of schedule with no safety incidents.

Work

Exxaro FerroAlloys
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Senior Production Controller

Pretoria, Gauteng, South Africa

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Summary

Led comprehensive production operations and resource management for Ferrosilicon processes, optimizing efficiency, ensuring quality, and driving cost reduction initiatives.

Highlights

Increased overall production output by 20% by improving process efficiency and integrating a previously underutilized by-product into the milling process, significantly boosting throughput.

Reduced operational costs by repurposing an unused by-product, transforming it into a commercially valuable input sold to external customers in the diamond sector.

Maintained consistent product quality by developing and implementing rigorous grading and sizing criteria, ensuring milled by-product consistently met strict diamond industry specifications.

Achieved a zero-incident safety record during process transitions and milling phases by implementing all changes in full alignment with internal safety protocols and legal compliance standards.

Optimized production efficiency and resource utilization by developing and maintaining robust production schedules and overseeing the allocation of materials, equipment, and personnel.

Exxaro Zincor
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Process Controller

Springs, Gauteng, South Africa

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Summary

Monitored production processes and managed product output, ensuring quality, efficiency, and compliance with operational guidelines and customer specifications.

Highlights

Ensured consistent product quality by monitoring production processes and conducting routine inspections, meeting both internal and customer specifications.

Coordinated daily production activities, adhering to approved work instructions and operational guidelines to maintain high levels of efficiency and compliance.

Managed the quality and quantity of finished products, ensuring client requirements and delivery expectations were consistently met.

Maintained effective cross-functional communication with maintenance teams and plant personnel to support smooth production operations and promptly resolve ad hoc issues.

Education

Tshwane University of Technology
Pretoria, Gauteng, South Africa

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Bachelor of Technology

Chemical Engineering

University of Johannesburg
Johannesburg, Gauteng, South Africa

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National Diploma

Chemical Engineering

Phala Secondary School
Bochum, Limpopo, South Africa

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Senior Certificate (Matric)

General Studies

References