Thuthuka Prince Khoza
Industrial Engineer | Lean & BPM Specialist | Business Analyst
Pretoria, ZA.About
Results-oriented Industrial Engineer with 5+ years of experience optimizing processes, improving performance, and leading Lean and Business Process Management (BPM) initiatives across diverse sectors including mining, telecoms, and FMCG. Skilled in applying Six Sigma, ISO standards, and data analytics, I deliver measurable improvements in productivity, cost savings, and operational excellence. Passionate about driving strategic change through data-driven continuous improvement methodologies and transforming complex challenges into efficient solutions.
Work
Midrand, Gauteng, South Africa
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Summary
Led the formulation and maintenance of Business Process Management policies, frameworks, and standards, driving continuous improvement and operational excellence across Liquid Intelligent Technologies South Africa.
Highlights
Developed and maintained the Business Process Management Policy, framework, and standards, ensuring the availability of policies, processes, and support documentation on a functioning portal.
Managed the delivery of BPM processes and standards, contributing to an integrated and effective end-to-end enterprise operating model.
Formulated and defined ISO Certification policy, framework, and calendar (ISO 9001, 20000, 270000), maintaining certification through planned audits.
Designed, developed, and maintained self-serve automated reporting, workflow, and productivity management tools to enhance organizational effectiveness.
Spearheaded the digitalization of business failure identification and reporting through a 'Process Failure App,' streamlining processes and driving continuous improvement.
Pretoria, Gauteng, South Africa
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Summary
Optimized production processes and enhanced efficiency through time studies, lean manufacturing initiatives, and workflow improvements, delivering measurable improvements in productivity and cost savings.
Highlights
Improved TL02 Overall Equipment Effectiveness (OEE) from 70% to 82%, significantly enhancing production line performance.
Reduced Chemico paste cycle time by 98.4%, dramatically improving product finishing and plant capacity.
Increased Chemico Liqui clean line speed by 11%, saving the plant R15,000 annually in maintenance costs and reducing spillage/stoppages.
Optimized OEE of haircare to 80% and reduced downtime through the Quantum lean project.
Digitized energy reporting by implementing Power BI, improving data accessibility and decision-making.
Belfast, Mpumalanga, South Africa
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Summary
Supported business improvement initiatives and operational excellence frameworks, focusing on process optimization, project implementation, and performance tracking across mining and beneficiation units.
Highlights
Improved onboarding processes and reduced turnaround time through the MRM checkpoint initiative.
Enhanced value chain and digital processes by contributing to the Northstar initiative.
Developed and managed Power BI reports for business reporting, improving data visibility for operational decision-making.
Supported the execution of the Business Improvement/Operational Excellence (OE) framework, facilitating breakthrough projects and knowledge transfer.
Assisted with process design, mapping, and re-engineering efforts to track metrics for efficiency and effectiveness.
Germiston, Gauteng, South Africa
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Summary
Drove continuous improvement initiatives focused on enhancing cost efficiency, product quality, and service delivery through 5S implementation, dashboard development, and process optimization.
Highlights
Managed 5S Implementation, training employees and deploying 5S across all facilities.
Reduced report compilation time by 40% through the development and design of dashboards, improving data accessibility.
Improved communication and reduced storage error and loading rate by 25% through new promotion launches simulations.
Evaluated diverse organizational systems to identify workflow, communication, and resource utilization issues, developing actionable improvement plans.
Ensured management systems (ISO 9001, ISO 14001, ISO 22000, ISO 45000) conformed to international standards, maintaining compliance.
Richards Bay, KwaZulu Natal, South Africa
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Summary
Conducted comprehensive industrial engineering analyses, including time studies and process mapping, to identify inefficiencies and implement performance improvement strategies in manufacturing operations.
Highlights
Reduced cylinder line pre-assembly and wash process cycle time by 30% through washing time improvements.
Decreased overall process cycle time by 10% and improved personnel utilization by balancing work allocation and reducing excessive motion.
Designed and implemented labor utilization standards to optimize efficiency across production stations.
Developed and executed performance improvement strategies and plans, promoting continuous improvement initiatives.
Conducted time and method studies, activity sampling, and root cause analysis to identify and resolve operational bottlenecks.
Richards Bay, KwaZulu Natal, South Africa
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Summary
Contributed to significant process optimization and waste reduction initiatives, leveraging Six Sigma and Lean methodologies to improve operational efficiency and cost savings within port terminal operations.
Highlights
Achieved an annual R180,000 saving by improving cycle time and resource utilization in Aluminium super pack performance.
Improved Ferro slab RMT offloading performance by 30%, enhancing processing time, queuing time, and resource utilization.
Utilized Six Sigma SIPOC and DMAIC processes to lead problem-solving efforts, resulting in updated processes and improved material flow.
Applied fishbone diagrams and Failure Mode Effects Analysis (FMEA) to resolve critical customer complaint issues.
Managed various projects independently and liaised with stakeholders to drive strategic process improvements and achieve target margins.
Education
Languages
English
Skills
Business Process Management (BPM)
Business Process Reengineering (BPR), Process Mapping, Process Optimization, Lean Six Sigma, DMAIC, Kaizen, Continuous Improvement, Workflow Improvement, Process Capability Analysis, Regulatory Process Compliance (ISO 9001 & 27001), Risk-Based Process Assessment, Digital Process Automation.
Data Analysis & Visualization
Data Analysis, Data Visualization, Dashboard Design, Data Processing & Transformation, Power BI, SQL, Microsoft Excel, Reporting Frameworks.
Project Management
Project Management, Implementation, Strategic Planning, Stakeholder Engagement, Problem Solving, Decision Making, Time Management, Cross-Functional Collaboration.
Operational Excellence
5S Implementation, Waste Identification & Reduction, Time & Motion Study, Productivity Management, Performance Management, Bottleneck Analysis, Root Cause Analysis (RCCA), Quality Management Systems, ISO Standards, Visual Management, Ergonomics Optimization.
Engineering Tools & Software
3D Modelling & Simulation, Arena Software, Flexsim, SolidWorks, SketchUp, AutoCAD, DraftSight, AS400, Windchill, Kenova, Lucidchart, LibreOffice, Microsoft Office, Microsoft Visio, Microsoft Teams, IBM Messenger, Shopware.
Communication & Leadership
Communication, Presenting, Team Facilitation, Training & Development, Teamwork, Leadership, Change Management, Conflict Resolution, Customer Focus (VOC), Curiosity & Courage, Creativity & Innovation, Emotional Intelligence, Ability to work under pressure.
References
Mr. S Essack
Owner of Leanbiz and Co-founder of Livefactory. Contact details available upon request.
Mr. T Hato
Snr Business Improvement Analyst, Exxaro Resources. Contact details available upon request.
Mr. V Xaba
Quality Technician, Quality Dept., GZ Industries. Contact details available upon request.
Miss. K Shoko
Process Improvement Specialist, PI Dept., GZ Industries. Contact details available upon request.
Mr. S.M Nxumalo
Mentor, Work Measurement Dept., Bell Equipment. Contact details available upon request.
Mr. M Mazibuko
Lecture, Industrial Engineering and Operations Management Dept., VUT. Contact details available upon request.