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CV For Senior Plant Manager Debre Birhan 28.03.21
CV For Senior Plant Manager Debre Birhan 28.03.21
SUMMARY
A dynamic, loyal, committed and trustworthy management professional with 28 years’ experience in a highly regulated
manufacturing industry, covering all areas of general management and customer-supplier relationship management. A
demonstrable track record in managing risk, improving customer relationships and operational efficiency.
Looking for a new challenge and an international opportunity where I can adapt, grow and bring my significant experience
to deliver success within the Boortmalt Group.
EDUCATION
University College, Cork, Ireland MSc, Food Science and Technology 1990 - 1993
EXPERIENCE
Boortmalt Group, a fully owned subsidiary of the agricultural and agribusiness cooperative Axereal, is the largest malting
company in the world, producing 3 million tonnes of malt in 27 malting plants across 5 continents and supplying malt to
global breweries and distilleries. The Athy site produces >140K tonnes of malt per annum and supplies malt to global
customers.
As Plant Manager, I am responsible for all aspects of the site from barley supply, malt production and delivery to customers.
This is achieved through leading a team of 4 direct and 23 indirect reports focusing primarily on safety, quality, production,
energy, cost, ISO and food safety standards. Daily management of the site is achieved through Boortmalt Operational
Excellence (BOPEX) methodology and focusing on continuous improvement initiatives.
Key leadership and management responsibilities, in line with the business values of care, strive, inspire, explore, include:
Safety:
Ensure the site is always safe and encourage a proactive approach to positive safety behavior.
This has resulted in >1295 days without a lost time accident and year on year improvements in people’s behavior.
Quality:
Aim is to achieve first time right (FTR) on all batches produced in the maltings.
Over recent years, this has resulted in an 8.1% increase in malt quality FTR score from the malting plants.
Customer:
Proactively work with all our customers to strengthen relationships and assist them in achieving their targets.
97.5% Diageo scorecard achievement for quality, service and CI customer projects.
Volume:
Operate the malting plant at maximum designed capacity to ensure minimum cost/tonne.
44% increase since FY11, record tonnage in FY19, 59% reduction in process downtime.
Utility:
As the biggest cost on site, manage gas/electricity/water usages very closely.
Since FY11 - 24% reduction in gas, 36% reduction in electricity, 51% reduction in water.
Other:
CSR - 28% reduction in CO2, >€18K raised for local charities.
Innovation – first ever production of wheat and rye malt, new craft malt business, Optisteep steeping process
Group initiatives - standardisation of steeping process, standardisation of EHS documents, ERP super user
Major achievements:
In 2016 the Athy site was selected as one of 2 showcase sites when Boortmalt implemented operational excellence standards
across their 10 sites in Europe. I led the project, through engagement with operations personnel, to develop a template in
order to capture, implement and communicate KPI information across the site. As a result, the Athy site team was awarded
the inaugural BOPEX award and went on to win the Boortmalt Malting Cup for best performing site in the same year.
Malting Production Manager, Boortmalt, Athy, Ireland Oct 2004 – Apr 2010
Day-to-day running of two production facilities on site yielding record tonnage of 97.7K malt tonnes in 2007
compared with previous maximum tonnage of 93K malt tonnes.
Improving business management systems on site to ensure continuous improvement in customer audit scores year
on year from 83% to 95%.
Integrated role involved working closely with the maltings manager, maintenance personnel and operators.
Responsible for deputising for Plant Manager as required.
Business Systems Manager, Boortmalt, Ireland and UK Jan 2003 – Oct 2004
Implementation of operational, capital and ISO systems to ensure that the requirements of an international brewer
were achieved.
Acting maltings manager as required.
Managed a €1.265M capital investment project yielding an increase in throughput of 23% and an energy saving of
€77K per annum.
Redefined and implemented a maintenance system to bring costs in line with budget, yielding savings of €150K
per annum.
Capital Projects and Health and Safety Manager, Boortmalt, UK Apr 1998 - Oct 2001
Managing all capital investment projects and Group insurers’ health and safety procedures at 9 manufacturing
facilities in the UK.
Prioritised, prepared, submitted and managed capital investment of €12.5M across 9 locations.
Member of the due diligence acquisition team for the purchase of the UK malting business.
Process Improvement and Energy Manager, Boortmalt, Ireland & Belgium May 1995 – Apr 1998
Investigated potential production process improvements and energy management leading to €3.2M capital
investment and savings of €500K in Ireland and Belgium.
Prepared and submitted multiple energy projects to the Irish Energy Centre resulting in grant aid of 30% for many
capital investments projects.
Assistant Production Manager, Dawn Dairies, Kerry Foods, Ireland May 1993 - May 1995
Day-to-day running of 3 intensive liquid milk manufacturing and packaging facilities in Galway, Cork and
Limerick over 2 years.
SUPPLEMENTARY COURSES/TRAINING
INTERESTS