Bsc. Food Science & Technology

Diploma in Applied Biology

Quality Assurance Manager

Responsibilities and Accountabilities

Ensure accepted technical & quality standards are fully implemented and customer satisfaction for all products to fully cover Safety, Quality, Legality and Authenticity. This is through the following:
1. Systems implementation and documentation and due diligence by:
a. Ensuring conformity and compliance of raw materials to all requisite government regulations & customer regulations
b. Developing, review and ensuring proper storage/availability of all documentations (Product specifications, SOPS, SSOPs, WIs, WLs, GFSI Certifications, Training documents, Customer complaints & feedback)
c. Carrying out internal audits (Building and fabrication audits, Hygiene audits, QMS, BRCGS, CCP Audits, Food Fraud and Defense audits) and representing the company with the annual external auditing processes.
d. Developing and implementing Supplier audit schedule and approvals, both internal and external.
e. Company Food Safety Team Leader chairing the monthly food safety meetings, quarterly HACCP meetings and annual management review meetings.
2. Skills & knowledge upskilling of QC & Production Staff by:
a. Heading a team of well trained and competent quality controllers & assurance who are motivated with the aim of ensuring that product quality is consistently achieved.
b. Planning of staff and equipment resources in advance to prevent interruptions to activities carried out by the quality department
c. Scheduling meetings with the relevant departments within the site to keep all updated on new legislation, standards and customer requirements
d. Conducting training needs assessments (TNA) for all employees
3. Product quality and safety:
a. Ensuring checks are done for all the raw materials to conform to the raw material specifications
b. Ensuring production process yield products that consistently satisfy the stated customer quality.
c. Customer complaints: Investigate all customer complaints, trending of such and ensuring corrective and preventative actions are put in place to avoid a recurrence. Also responsible for developing and implementing a customer complaint reduction plan.
d. New Product Development and looking at new concepts that can be trialed with the current HACCP
e. Discussing NPD on behalf the site during the company’s Technical meeting.
4. Machines and Equipment
Managing of all the equipment and tools within the packhouse to ensure optimal performance through scheduled preventive maintenance, training of operators, verification checks and safe storage when not in use. This is achieved by developing and ensuring implementation of Planned Preventive Maintenance (PPM) for all the equipment in collaboration with the plant engineer.

5. Recipe Management
a. Aligned to customer specifications and cost effective BOM formulations.
b. Follow up on getting all new products specifications developed and approved for use by the pack house in liaison with the sales team
c. Labels control, line clearance and packing controls to ensure product legality
6. Hygiene: Responsible for all the Packhouse hygiene related matters and ensuring validation of hygiene through ATP rapid tests and external micro analysis.

7. Packhouse supplies/ Inventory management: Contact person for all packhouse process aid requirements including detergents, QA consumables and all the chemicals. This is achieved by liaising with the procurement, production and maintenance in getting the required specifications approval before purchase or re-supply.

8. Improving production efficiency and managing wastes while ensuring that quality is maintained across the supply chain.

Achievements
 I helped the company attain AA+ (the highest BRC grade under Un-announced audits) in 2023-2024 BRCGS external audit
 I reduced the number of customer complaints by 50% in 2023 YTD as compared to 2021-2022 same time.
 I introduced a system for Environmental pathogen monitoring program which is now currently being used in all the AAA Growers packhouses
 I developed Standard Operating Procedures, Sanitary Operation Procedures and Work instructions which aided the company achieve the current AA+ Grade.
 I mentored my team to be able to run multiple operations through the use of a training matrix hence building a solid team which can work in any section of the packhouse.

Quality Assurance & Safety Manager

Responsibilities and Accountability
1. Food Safety & Hygiene: Ensure food safety in the Company by:
a) Providing leadership as the company food safety team leader and ensuring that the company is compliant with the latest food safety regulations.
b) Implementing food safety initiatives and overall HACCP plan in the company’s food chain.
c) Collate and analyse data and contribute to the preparation of reports relating to food quality and safety, food incidents, supplier performance, to inform risk management and mitigation and contribute to the company’s wide view of food safety and quality activities
d) Prepare evidenced-based recommendations for management staff on control measures to mitigate Food Quality, Food Safety, Food Authenticity, Legality and Health & Safety issues.
e) Prepare evidenced-based recommendations for management staff on tools to enable rapid response to situations with food safety concerns e.g. product recall, fire incidences
f) In the event of food safety incidents, near-misses or accidents, support investigation exercises to enable lessons learned to be documented and shared, to reduce the re-occurrence of the incident. Also co-ordinate communication with the DOSHS.
2. Raw Material and Packaging Material Quality: Ensure purchase of quality raw material that guarantees quality products by:
a) Undertaking supplier inspections and risk assessments in order to establish safety and quality of the source of raw materials and packaging materials
b) Providing professional and or technical advice in buying tea, herbs and packaging materials.
c) Inspecting the quality of raw material and packaging materials for conformity to set standards
d) Working in the development and implementation of key food safety and quality programs for the organization, such as supplier audits, food and packaging inspections, food compliance testing, HACCP studies, HACCP Plan development, among others. Contribute to the development of appropriate risk management tools for new modalities of food/packaging purchase and distribution
3. Product Quality: Maintain set product quality by:
a) Performing product tasting and advising on blend formulations.
b) Setting operational standards to be followed based on regulatory requirement.
c) Examining product quality defects and analysing the defect cause and establishing corrective/ preventative actions.
d) Carrying out supplier audits to ensure compliance to the set standards
4. Production Standards: Ensure adherence and compliance to set standards by:
a) Documenting all the standards and make them readily available when needed
b) Updating food safety manual, material data base, training staff and maintaining hygiene
5. People Development: Carry out Training Needs Analysis (TNA) and come up with training topics to to address the employee gaps and make sure that they understand how to apply the standards and maintain product quality/knowledge.
6. Customer Satisfaction: Ensure that products meet and surpass customer expectations by:
a) Working closely with the customer experience executive to get feedback on the desired product characteristics
b) Handling customer complaints and giving immediate feedback by correcting the non-conformities in products, replacing the goods for them and changing product formulas to suite market needs
7. Industry Trends: Ensure that the Company keeps itself abreast with industry trends by:
a) Researching and advising the leadership on industry trends that affect its business operations
b) Representing the company in meetings that have quality effect on food product standards in order to keep track on changes taking place in the production environment
8. New Product Development:
a) Support continuous new product development to meet consumer expectations by playing an advisory role on Product development and design thinking in order to come up with products of high quality and solve a certain problem in the market.
b) Work in the research and development/improvement of foods, including supporting specifications, scientific-based studies like shelf-life studies and trials
c) Manages the Stage gate process of product development and ensuring approvals in every stage gate.
d) Panel team member fo artwork approval as per the company/customer requirements
9. Ensure compliance to relevant guidelines, Controlled Documents, and study plans/protocols by performing:
• Specific audits on the critical phases identified for a study
• Audits on study plans/protocols and final study reports, including amendments
• System/facility and process audits as per audit plan/matrix
• Perform Subcontractor and Outsourced Company evaluations, risk assessments and audits
• Prepare and issue audit reports and document findings, observations, and critical findings
• Perform annual review of Controlled Documents or when needed.
• Develop, recommend, and monitor corrective and preventive actions and communicate to relevant management
• Manage the Master Schedules and files, both internal and external.
• Support audits and Regulatory inspections performed at the organization
• Support in the training of personnel in GLP and GMP principles and of Quality Assurance SOPs, SSOPs, WIs & WLs
• Maintain internal training compliance
• Manage the company’s compliance to accreditation, legal and regulatory requirements
• Manage reporting employees with the intent to promote a culture that reflects the organization’s values, encourages good performance and rewards productivity
• Observe the correct reporting, remedial and corrective actions to be followed by following set instructions and procedures to report and correct any non-conformance issues.

Achievements
 In a short period of six months, was able to successfully complete and launch six products that have gone to the market with a good market reception (Purple Bliss, Green Tea with Tangawizi, Variety of Teas, Medley of Infusions, Pure Green & Herbal Salt)

Projects
 Formulated Detox Tea, Slimming Tea, Gold Tea and Vanilla Caramel Tea until completion, currently on sale in both local and export markets.

Ag. Production Manager

Responsibilities and Accountabilities
1. Strategy formulation and execution: formulate and execute the production strategies and budgets to ensure that production operates optimally and is aligned to the overall organizational goals and objectives. Lead on strategic analysis in areas including business model design, customer and market research, supply chain, pilot designs, Product developments, process improvement and strategic partnerships.
2. Budgeting: Regularly prepare budgets and cost estimates for production in order to manage the cost of production in real time.
3. Production Planning: Ensure timely production planning through:
a) Work closely with the sales administrator in forecasting production demand by forward planning and execution of production plans.
b) Planning and organizing production schedules
4. Production Execution: Ensure a smooth production flow by:
a) Timely assembling of required raw and production material in order to produce sufficient and quality products meeting market demand and expectations.
b) Allocating work to production staff by dividing responsibilities and tasks across the team to make production more efficient.
c) Achieve the Production Target as per the Production Plan by setting up, monitoring and verifying all production targets of the day.
5. Production Monitoring: Monitor production activities to ensure production of quality products by:
a) Adhering to the specified standards in order to sufficiently meet market demand for great customer experience.
b) Ensure that all quality products produced are kept in the right place in the store and registered in the SAP system for their safety, easier access and accountability.
6. Production Efficiency: Attain set production efficiency by:
a) Ensuring all production machines and resources are working and in good condition to achieve set standards of Overall Equipment Efficiency (OEE). This was achieved by following the “Center-Lining Principle” which focuses on optimization of machines to improved productivity and quality. We set the desired running conditions which will be followed by all the team members for full optimization which will in turn improve the OEE
b) Ensuring minimal waste generation during production by training, implementing, monitoring and evaluating waste generation minimization activities through Lean manufacturing.
c) Enforcing asset care practices to enhance efficiency and life of the production equipment. This is achieved through Preventive Plant Maintenance programs hence preventing unnecessary plant downtimes.
d) Track the plant performance metrics and lead the conception and implementation of methods that improve efficiency, utilization rate, productivity year on year on quality and production costs with the aim of achieving world class utilization standards and improved pack outs.
e) Create an environment that supports the development and implementation of new ideas, improved methods, systems and work processes that will lead to reduction of production/operational costs. This is achieved by encouraging a positive food safety culture where all the employees are engaged in the generation of improvement ideas and rewarding/acknowledging them.
f) Drive the utilization of available automation in the day to day operations.
7. Team Management: Cultivate a high-performance culture by:
a) Communicating company policies to production staff through training, sensitization and enforcing the policies in order to achieve high performance and great staff experience.
b) Maintaining discipline among production staff through training, sensitization and enforcing of production rules, regulations and the company code of conduct for great staff experience. Food safety culture is gauged through questionnaires to all the company employees and all the gray areas taken into an action plan for formulation of a corrective and preventative action plan.
c) Ensuring great staff experience by assigning roles, tasks to each and compensating them accordingly.
8. Compliance: Drive compliance with all food safety, quality, health & safety and environment standards, policies, customer specifications and procedures in the plant through training, reviews and taking corrective/preventative actions where there is non-compliance in the factory.
9. Reporting: Compile factory reports from the section heads to aid in planning, decision making and strategy review by the company board.
10. Packaging/Labels product development: Responsible for artwork approvals as per the company and customer requirements.
11. Brand Representation: Represents the company in high profile company meetings like the board meetings, stake holder meetings, external meetings and exhibitions.

Team Leader Health, Safety, Quality Control & Assurance

Responsibilities:
 Prepared the daily shift reports on quality
 Carried out risk assessments and consider how risks could be reduced though risk based or process based thinking
 Conducted safety Toolbox talks to employee
 Site inspections to check whether policies and procedures are being properly implemented
 Led the department in carrying out monthly EHS meetings
 Led in carrying out incident/accident investigation
 Led teams in Root Cause Problem Solving (RCPS) for all quality/process deviations and non-conformances.
 Interpretation of SPC charts to teams
 Leading QC Team in participating in Lab/process trials and provide timely analysis reports to section managers.
 Led QC team in the implementation of the 4Q and World Class Operations Best Practices
 Training of new employees and interns on the use of SPC charts
 Prepared daily, weekly and monthly reports on departmental quality, health and safety
 Participated in Food safety and HACCP plan implementation
 Provided leadership, guidance, and motivation to direct reports – enabling them to achieve key performance indicators. Also responsible for scheduling work assignments
 Plan and participated in conducting internal and external audits like FSSC22000:2018, ISO9001:2015, RA/UTZ, ISO 45001:2018
 Conducted customized coaching and training sessions based on Quality Audit results and requirements of different customers.
 Process validation, cleaning validation and analytical method verification and validation
 Preparation and standardization of different chemical solutions of varying concentrations for analytical purposes
 Data capture and record keeping of analytical results
 Responding to customer complaints by participating in root cause problem solving
 Planned and initiated Ring Test programs aimed at determining or establishing the analyst competencies with the aim of targeting <2 Z score.  Quality approval of finished products in SAGE X3 (ERP) & generate weekly FTR reports for management review.  Worked proactively with various levels of staff & managers to establish and maintain a safety culture in order to sustain Zero harm goal across the organization.  Work proactively with various levels of staff & managers to ensure full implementation of ISO 45001:2018 in all departments by taking part in internal audits.  Ensured that the standard operating procedures and work instructions are up to date through reviews.  Regularly evaluating the effectiveness of training and develop appropriate training solutions/changes to ensure a high level of quality and competency of Staff. This is done though Formal/Informal coaching and appraisals.  Assist in the development of appropriate training matrixes for technical staff Achievements  Enabled Shift B to be best performing shift for the year 2019/2020 in powder & Liquor FTR through effective process control mechanisms and feedback.  Enabled the Technical department to be recognized as the best performing in Health and safety by leading in Risk assessments and review of safe working procedures.  Successfully participated in internal audit and implementation of ISO 45001:2018 for initial certification. Projects  Participated in Experiments/Trials which have a potential order of over 100MT per year.  I was part of a selected Centre-Lining Taskforce aimed at having Optimization of machines to improved productivity and quality. We set the desired running conditions which will be followed by all the team members for full optimization which will in turn improve the OEE.  I was also part of “Rejesha Aroma Project” aimed at improving the volumes and quality of tea extract aroma from the spinning cone columns (SCC). The success of the project would ensure sustainable business for Tea Extracts Ltd in Europe, Asia and American markets dominated by competitors from China and Argentina.  I’m was part of Quality Internal Taskforce (QITF) aimed at focusing on “Quality at Source”. The project was part of the 4Q strategy of provision of business intelligence to Operations department to reduce waste & improve efficiency, thereby lowering cost, driving consistent quality product that meets and exceeds customer expectations.  Led a team of Non-managerial workers in a two-week workshop in worker participation/consultation in accordance with ISO 45001-2018. The workshop played a major part in certification process.

Tea Tasting Analyst

Responsibilities:
 Preparation & participation in tea tasting session with a panel of tea tasting comprising of mid-level and top management
 Ensuring all the quality parameters desired are within specifications and planning for appropriate action in case of a deviation in the parameters
 Preparation and dispatch of pre-shipment and other samples as required
 Carry out routine calibration and maintenance of lab equipment in accordance with the documented laboratory quality management system to ensure integrity of the results.
 Implement and maintain good lab practices (GLPs) and Good Manufacturing Practices (GMPs)
 Drafting and circulation of final product approval sheet
Achievements
 Participated in New Product Developments (STD 658 & STD 657) which were successfully adopted in the global markets.

Quality Control Analyst

Responsibilities:
 Carry out laboratory analysis of parameters such as pH, turbidity, L* a*b*, % moisture content, density, ash content
 Carry out catechins analysis by use of high-performance liquid chromatography (HPLC)
 Carry out routine calibration and maintenance of lab equipment in accordance with the documented laboratory quality management system to ensure integrity of the results
 Implement and maintain good lab practices (GLPs) and Good Manufacturing Practices (GMPs)
 Record keeping of analytical results; periodic check of critical control points
 Ensuring all the quality parameters desired are within specifications and planning for appropriate action in case of a deviation in the parameters