Michael Afolabi
Winnipeg,Canada
Summary
Results-oriented Professional Engineer and Certified Six Sigma Black Belt with over a decade of experience in engineering and continuous process improvements across the Food Manufacturing and Mining industries. Demonstrated expertise in implementing Lean Six Sigma methodologies that yield substantial efficiency gains and cost reductions. Strong leader in operational enhancements, skilled in strategic planning, team leadership, and project management. Noteworthy accomplishments include innovative solutions that enhance quality standards and optimize performance metrics at all organizational levels.
Overview
13
13
years of professional experience
1
1
Certification
Work History
Six Sigma Black Belt
Maple Leaf Foods Inc
Winnipeg, Canada
01.2022 - Current
- Leads and supports process improvement efforts within Maple Leaf Foods; as well as externally to strategic customers, suppliers, and other stakeholders
- Focused on improvement efforts to build organizational capability to deliver process improvements, increasing business productivity, shareholder, and customer value
- Supports execution of site objectives
- Assisted with the identification and quantification of Critical Business Needs (CBN) and primary opportunities for improvement
- Facilitates Continuous Improvement process with cross-functional site teams including setting of annual OEE improvement targets and facilitating weekly status reviews and action planning
- Supports the facilitation and development of the site CI plan including project pipeline and monitoring the overall progress and status of the plan
- Ensures CI project teams are utilizing the appropriate improvement methodology (Six Sigma, Lean, OpEx tools), provides training and coaching on tools and application as required
- Conducts business case and risk analysis
- Provides CI Project Management support utilizing DMADV / PDCA framework
- Ensures sustainable results through application of change management and pragmatic control plans
- Provides coaching to leaders on Six Sigma, Lean and OpEx methodology & tools
- Supports Site Leaders in deployment of Operations Excellence framework including annual baseline assessment and pillar team deployment
- Leads the Waste Elimination teams to build operator skills at identifying and eliminating waste
- Assists with the identification and quantification of major opportunity areas, including the reapplication of learning across MLF
Reliability Engineer
Vale
Sudbury, Canada
03.2020 - 01.2022
- Reliability Engineer, part of the Integrated Asset Management organization and responsible for delivering improved performance of assets by implementing and optimizing reliability program for Copper Cliff mine complex (fixed and mobile plants)
- Ensured compliance to the reliability program and that asset reliability risks are identified and mitigated appropriately
- Provided recommendations on strategic investment in equipment, technology and initiatives to optimize asset value
- Developed Asset Strategy (Identifying asset criticality to the business, setting service strategy based on performance required, and driving reliability and cost-effective life cycle management) using tools like RCM and FMEA
- Liaised with Operations, Maintenance and Project teams to determine the appropriate operating standards and mix of preventative and predictive tasks required to optimize the reliable output of the assets
- Conducted Reliability Analysis and Improvement (Analyzing trends, KPIs - OEE, MTTR/MTBF, data analysis, root cause analysis - RCA, bad actor failure analysis and optimization) on systemic reliability issues and one-off significant events
- Provided design input to engineering and project teams on identifying components, assets and systems that are high contributors to unreliability and pose HSE and business risk
- Provided input to designs to drive improved life cycle costs
- Developed and maintained scopes of repair for repairable spares held in inventory and QA/QC requirements to ensure parts and equipment retain full reliability while stored
- Worked with site resources (operators and/or trades people) to optimize task methodology, content and sequencing of work to provide the safest and most efficient execution of work
- Supported 3rd party assessments/audits ensuring that critical operating and maintenance strategies are executed as per design
Project Engineer
Nestlé
, Nigeria
08.2017 - 05.2019
- Project engineer, provided support to the End-to-End Project Manager and Project Engineering Manager in developing the investment project charter and provided data and evidence to support technical and financial justification of capital projects and expenditure, cost benefit analysis and equipment selection
- Ensured design, implementation and start-up phases of capital investment projects (buildings, equipment erections, piping, utilities, etc.), in line with the investment project charter, design specifications and standards
- Produced basic and detailed design of the project based on Nestlé Corporate Business Principles, Nestlé standards, local regulations, the defined User Requirements Specifications and the TPM characteristics of a unit operation (safety, quality, affordability, maintainability, operability and reliability)
- Ensured all assigned projects are carried out in line with all applicable regulations comprising of safety and environmental regulations, hygienic engineering, sanitary design, good manufacturing practices, OSHA, and all governmental regulations
- Managed Design Qualification, factory acceptance tests (FAT), Installation Qualification (IQ), Commissioning and site acceptance tests (SAT)/User Acceptance Testing (UAT)
- Managed engineering side, including cost studies and lead-time estimation of assigned capital investment projects in accordance with the defined timing, cost and quality, the URS and the characteristics of a unit operation
- Provided leadership and support to the factory in identification, analysis and implementation of various cost savings and improvement projects on routine basis
- Ensured timely communication with appropriate stakeholders for changes to approved scope, quality, cost and schedule with strict adherence to the Change Management Procedure
- Supported the start-up manager and their team to ensure a smooth transition of project to operations
Continuous Improvement (TPM) Manager
Nestlé
Douala, Cameroon
03.2017 - 08.2017
- Factory TPM Manager, providing expertise and leadership to factory management for the implementation of TPM methodology in the multi product Douala factory
- Led TPM implementation in all 3 plants in the factory, managed TPM master plan, Pillar implementation plan and monitored roll out plans versus actuals and provided adequate support to be on track
- Acted as the single point of contact in the Factory for all TPM Initiatives
- Established an adequate structure and resources allocation to support effective roll out of TPM Initiatives according to the NCE Operating Framework and TPM Reference Guide
- Performed regular TPM assessment to ensure the correct application of methods, coaching and knowledge sharing, prepared reports and recommendations/action plan to meet phase change criteria
- Organized and managed routine reviews and activities
- Ensured all pillars and workgroup are on track
- Facilitated various workshops, including Team building, Zero loss journey and various pillar workshop
- Provided daily, weekly, monthly and quarterly reports to relevant stakeholders about the progress and status of TPM Initiatives
- Coordinated periodic rewards and recognition activities
- Supported various cost optimization projects
- Provided training on CI tools and techniques and help the teams achieve their targets by coaching
- Identify process improvement needs with department heads, facilitate sessions and support execution of newly established improvements validate outcome benefits and support creation of new standards
Maintenance Supervisor - TPM PM Pillar Coordinator
Nestlé
, Nigeria
08.2014 - 02.2017
- Factory-wide maintenance and continuous improvement support across a diverse range of equipment and processes in the 80,000 Tons/annum capacity Flowergate factory
- Maintained and troubleshooted a wide range of culinary production and manufacturing process equipment comprising 2 mixing lines, 70+ press and wrappers, 25 product counters, 12 baggers and over 20 conveyors equipment in this Nestle facility
- Exceptionally provided support for 20+ technicians across all four (4) shifts of 24hr production plants, tasked with preventive and periodic maintenance and resolution of issues across a wide range of equipment and processes
- As the PM Pillar coordinator, took ownership of all PM systems and work process in the plant and led the shop floor implementation using the pilot approach
- Facilitate the Implementation of reliability programs including Reliability Centered Maintenance RCM, Condition Based Monitoring, FMEA, TBM and Criticality Analysis
- Managed total plant's maintenance plan (Bill of Materials, FLOCs, Task Lists, work orders) update, execution, review and ensure technical completion (TECO) on SAP
- Conducted assets intensity analysis and monitored maintenance KPIs - OEE, MTBF, MTTR, MTBS
- Led troubleshooting and problem-solving activities, providing solution for equipment, process, and quality related issues leveraging tools such as RCA, Breakdown Analysis, Gemba walk etc
- Collaborated and implemented proactively with production, utilities, and demand planning teams; shutdown and start-up work programs to minimize the risks to the people, product, and processes
- Provided technical support to the project management team as needed for factory capital expense project implementation and review for adherence to standards
- Collaborated with maintenance & production teams, external contractors, and factory management on improvement projects with emphasis on cost reduction, quality improvements, capacity increase and optimized utility consumption
Management Trainee
Nestlé
, Nigeria
08.2013 - 08.2014
- One year cross functional/business training across Nestle's country operations with focus on engineering manufacturing and utilities generation
- Completed sales market survey, data analysis and interpretation in the Lagos open market and supermarkets while working with the sales administration team, helping the team to understand consumer behavior assisting in daily sales decision-making process
- Completed a research project to return AHU condensate water to the cooling tower to improve cooling efficiency by 5% which translated to 3% total factory energy cost
Assistance Site Engineer
Hurlag Technologies Ltd
Lagos, Nigeria
05.2013 - 07.2013
- Supervised the piping installations of the newly installed 60,000 bottles/hr packaging line 3 at Consolidated Breweries (now Nigerian Breweries), Ijebu Ode Plant
- Work scope includes Interpretation of Drawings, Pipe support design, Pipe Welding (TIG) and Fittings Connection, Pasting, Insulation, Cladding etc
- Achievement of Zero Incident as Site/Project Safety Officer, responsible for preparing Work Permits, Ensuring and enforcing workplace safety procedures on site
Computer Aided Design Specialist/Trainee Engineer
Lottoj Penta
Oshogbo, Nigeria
08.2012 - 04.2013
- Facilitated training of various clients (Students, Technicians and Professionals), on various Autodesk CAD software applications
- Produced engineering design drawings for various clients, of engineering and architectural background using CAD software
- Supervised of design and fabrication of machines and creates digital prototypes of various designs
Computer Aided Design Specialist
BASICON Engineering Company Limited
Owerri, Nigeria
08.2011 - 07.2012
- Produced models of various machineries using Autodesk Inventor Software for Tenders and working drawings for shop floor Technicians
- Supervised machine fabrication and installation and ensure compliance to design specifications
Education
Master of Engineering Management - Project Management
University of Ibadan
01.2017
B.Tech(Hons) - Mechanical Engineering
Ladoke Akintola University of Technology
01.2010
Skills
- Project Management
- Lean six sigma methodologies
- Change Management
- Process Improvement
- Continuous Improvement
- Operational Excellence
- Strategic Planning
- Total Productive Maintenance (TPM)
- Computer-Aided Design (CAD)
- Microsoft Office tools
- Minitab
- Root Cause Analysis
- Engineering Drawings
- SAP
- Problem solving
- Kaizen
- Value Stream Mapping
- Process Mapping
- DMAIC
- PDCA
Certification
- Project Management Professional (PMP)®
- Professional Engineer (PE)
- Lean Six Sigma Black Belt
Careerachievements
- Efficiently managed capacity improvement projects valued at USD 30M for Nestle's Flowergate factory within 22 months period. Achieved 100% vertical start-up for 5 major projects using the TPM Early Management methodology.
- Completed the mechanical installation and commissioning of a 6 floor 100,000 Tons/annum capacity 'mixing tower debottlenecking project' to increase production capacity by 100%. Project valued at USD 12M.
- During a 6-month expatriation mission assignment at the multi product Douala Factory in Cameroon. Successfully managed implementation of Nestle's continuous improvement initiative (TPM). Achieved 100% synchronization of all TPM pillars and 100% implementation of roll-out plan, helping the factory to increase in Factory Asset Intensity by 10% and to pass the phase change assessment to move from a phase 0 to a phase 1 manufacturing facility.
- As the factory PM Pillar Coordinator, effectively led a 20+ multi-disciplinary team of engineers, technician and operators to implement TPM PM Pillar Methodology at Flowergate factory helping the factory to successful phase changes twice from 0 to 1, then to 2 and making the factory the 2nd TPM phase 2 factory in Africa after Egypt.
- Led the implementation of the Reliability - Failure Analysis Loss Profile routines. Also supported the team to achieve 100% implementation of Vale Production System (VPS) on priority A assets for the underground Mine (VALE - North Mine).
Accomplishments
- Winner of disciplined decision making annual Maple Leaf Foods CEO award 2023
Timeline
Six Sigma Black Belt
Maple Leaf Foods Inc
01.2022 - Current
Reliability Engineer
Vale
03.2020 - 01.2022
Project Engineer
Nestlé
08.2017 - 05.2019
Continuous Improvement (TPM) Manager
Nestlé
03.2017 - 08.2017
Maintenance Supervisor - TPM PM Pillar Coordinator
Nestlé
08.2014 - 02.2017
Management Trainee
Nestlé
08.2013 - 08.2014
Assistance Site Engineer
Hurlag Technologies Ltd
05.2013 - 07.2013
Computer Aided Design Specialist/Trainee Engineer
Lottoj Penta
08.2012 - 04.2013
Computer Aided Design Specialist
BASICON Engineering Company Limited
08.2011 - 07.2012
Master of Engineering Management - Project Management
University of Ibadan
B.Tech(Hons) - Mechanical Engineering
Ladoke Akintola University of Technology
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