Hi, I’m
Johnson Kalu
Saskatoon,Saskatchewan
Summary
Seasoned Production Manager with over 15 years of experience in the food processing industry, including roles as Plant Manager and Production Supervisor. Expert in leading large teams, optimizing production processes, and driving continuous improvement initiatives. Proven track record of managing operational costs, ensuring compliance with safety and food safety regulations, and fostering positive employee and union relationships. Skilled in implementing Lean and Six Sigma methodologies, enhancing operational efficiency, and supporting product development.
Overview
17
years of professional experience
1
Certificate
HIGHLIGHTS OF QUALIFICATIONS
- Food Safety Expertise: In-depth knowledge of CFIA, HACCP, SSOP, and Pre-requisites.
- Leadership & Team Management: Managed teams of 100+ staff with 5-7 direct reports.
- Continuous Improvement: Certified Six Sigma with Lean methodologies experience.
- Cost & Safety Focus: Ensured cost-effectiveness without compromising quality or safety.
- Stakeholder Management: Engaged effectively with unions, suppliers, and contractors.
Work History
Crestline Coaches Limited
Snr. Production Supervisor
09.2023 - Current
Job overview
- Operations Leadership: Managed daily operations, including manufacturing, maintenance, warehousing, fleet management, and export processing for ambulance and bus production. Implemented processes to maximize efficiency, safety, quality, and compliance.
- Safety & Compliance: Established a focused safe working environment. Ensured compliance with WorkSafe, Occupational Health and Safety, and HACCP/CFIA regulations, leading initiatives that significantly reduced lost time and medical aid incidents.
- Production & Cost Management: Applied methodologies to optimize manufacturing and maintenance processes. Grew production by 27% year-over-year by reducing overproduction hours by 18% for ambulances and 17% for remounts. Achieved cost-effectiveness while maintaining high quality and safety standards.
- Team Management & Development : Guided and developed employees and management team. Introduced a perfect attendance scheme and leadership training for team leads, reducing attrition by 11% and absenteeism by 19%. Created robust employee development and succession plans, conducted performance reviews, and maintained effective communication practices.
- Customer & Quality Focus: Maintained strong customer relationships and ensured product specifications met customer expectations. Collaborated with engineering to enhance manufacturability of ambulances, reducing waste identified through Kaizen initiatives.
- Continuous Improvement & Innovation: Fostered a culture of continuous improvement by leveraging tools such as 5S, Root Cause Analysis, and Problem Solving. Managed process reengineering and supported innovation from concept to commercialization, benchmarking industry best practices.
Maple Leaf Foods
Production Manager
09.2022 - Current
Job overview
- Leadership & Team Development: Lead and engage all site employees and management to meet company goals. Developed robust succession plans and ensured effective communication and performance management across the team.
- Production & Cost Optimization: Managed production operations with a strong focus on cost control and efficiency, reducing site costs by 8% year-over-year while maintaining product quality and safety. Achieved 99% on-time, in-full (OTIF) order fulfillment rate.
- Safety & Compliance: Ensured compliance with WorkSafe and food safety programs (HACCP, CFIA), maintaining a zero lost-time incident rate over the past two years and achieving top ratings during audits.
- Continuous Improvement: Applied Lean and Six Sigma methodologies to streamline operations, reducing waste by 15% and increasing efficiency. Supported innovation that expanded plant capacity by 20%.
- Customer & Supplier Relations: Maintained strong relationships with customers and suppliers, reducing customer complaints by 25% and enhancing supplier responsiveness.
UAC Foods
Plant Manager
05.2018 - 01.2022
Job overview
- Leadership & Oversight: Led a team of over 150 staff with 7 direct reports, including the Production Manager, HR Manager, Safety & Quality Manager, and Warehouse Manager. Fostered a culture of accountability and performance, ensuring alignment with company goals.
- Operational Excellence: Directed all plant operations, from production and warehousing to safety and quality control, achieving a 15% improvement in overall operational efficiency through process enhancements and effective resource management.
- Safety & Compliance: Ensured compliance with safety, health, and quality standards, successfully reducing workplace incidents by 20% and maintaining top-tier audit scores for both internal and external inspections.
- Cost & Performance Management: Managed the plant's P&L, focusing on cost reduction strategies that resulted in a 12% decrease in operational costs while enhancing product quality and delivery timelines.
- Team Development & Succession Planning: Implemented training and development programs that improved staff skills and promoted succession planning, resulting in a 30% internal promotion rate within key departments.
Fidelity Bank PLC
Private Banking Relationship Manager
03.2009 - 06.2018
Job overview
- Performed banking, business administration and financial tasks to guarantee five-star service for clients which resulted to over 25% deposit growth.
- Collaborated with C-level executives and stakeholders to develop long-term financial plans.
- Utilized financial software to prepare consolidated financial statements.
- Established internal audit procedures to validate and improve accuracy of financial reporting.
UAC Foods
Production Manager
09.2012 - 05.2018
Job overview
- Operational Management & Cost Control: Accountable for production costs, labor utilization, and yields in the Raw area. Implemented cost improvement strategies and optimized manufacturing results to enhance operational efficiency.
- Team Development & Leadership: Developed a cohesive and competent team of Production Supervisors through training, coaching, and succession planning. Fostered a positive work environment by providing clear roles, consistent feedback, and maintaining strong union and employee relations.
- Safety & Compliance: Championed a robust safety culture, ensuring compliance with H&S and food safety standards.
- Production & Process Optimization: Optimized weekly and monthly production schedules, leveraging state-of-the-art automation. Conducted regular audits of processes, including People Systems, FSQA, and predictive reliability practices.
- Cross-Functional Support & Innovation: Supported Marketing and Sales in new and existing product development initiatives. Conducted weekly team meetings to review KPIs and drive continuous improvement across various operational areas.
Fidelity Bank PLC
Treasury
01.2008 - 03.2009
Job overview
- Prepared corporate fiscal and business plans to help strategically direct business operations and strengthen controls.
- Communicated with bank members and auditors on accuracy and timeliness of financial reports.
- Mitigated risk by implementing internal controls and safeguards for revenues and expenditures.
- Handled cash flow, debit and interest schedules and bank accounts with less than 1% error.
Education
Robertson College Winnipeg, MB
Diploma from Data Analysis
01.2024
University of CalabarCalabar Nigeria
MBA from Business Administration
04.2010
Abia State University UturuUturu Abia State Nigeria
Bachelor of Science from Microbiology
03.2005
Tekedia InstituteLagos Nigeria
MBA from Business Administration And Management , Mini MBA
04.2019
Skills
- Leadership & Team Building
- Continuous Improvement (Lean, Six Sigma)
- Cost Control & Process Optimization
- Food Safety & Compliance (HACCP, CFIA)
- Analytical Problem-Solving & Critical Thinking
- Stakeholder & Union Relationship Management
- Value Stream Mapping
Certification
- Canadian Certified Food Production Supervisor (CCFPS)
- Leadership skills for FrontLine Managers
- Food Processing - Operational Leadership course
- Lean Six Sigma
Availability
See my work availability
Not Available
Available
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Timeline
Snr. Production Supervisor
Crestline Coaches Limited
09.2023 - Current
Production Manager
Maple Leaf Foods
09.2022 - Current
Plant Manager
UAC Foods
05.2018 - 01.2022
Production Manager
UAC Foods
09.2012 - 05.2018
Private Banking Relationship Manager
Fidelity Bank PLC
03.2009 - 06.2018
Treasury
Fidelity Bank PLC
01.2008 - 03.2009
Robertson College
Diploma from Data Analysis
University of Calabar
MBA from Business Administration
Abia State University Uturu
Bachelor of Science from Microbiology
Tekedia Institute
MBA from Business Administration And Management , Mini MBA
Volunteering
Board Member 2018-Present
Gender Curriculum Advisor (E-Volunteer)-Lagos Nigeria
An NGO positioned an international organization working to achieve gender equality and women’s human rights across Nigeria.
Board Member 2020-Present
Lagos Food Bank
A NGO dedicated in ending poverty and protecting dignity of people. It works around the world to save lives, defeat poverty and achieve social justice
LANGUAGE COMPETENCIES
English- Native Language
LANGUAGES
- English Language- Fluent
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