Summary
Overview
Work History
Education
Skills
Training
References
Timeline
Generic

Daniel Simmons

Patterson Lakes,VIC

Summary

Experienced Operations Manager adept at improving output, maximizing quality and boosting employee satisfaction with hands-on management style. Recognized as effective business manager and motivational leader. Successful manufacturing management career spanning 20 years. Encouraging manager and analytical problem-solver with talents for team building, leading and motivating, as well as excellent customer relations aptitude and relationship-building skills. Proficient in using independent decision-making skills and sound judgment to positively impact company success. Dedicated to applying training, monitoring and morale-building abilities to enhance employee engagement and boost performance.

Overview

15
15
years of professional experience

Work History

Plant Manager – Bakery

Laurent Bakeries
07.2023 - 10.2023
  • Hands on management of 180 + direct reports including production supervisors, line operators and casual staff 24/7.
  • Responsible site management of a high-speed automated production line running at 6,500 units p/h, 2 x semi-automated production lines, handmade bread production area, 3 x automated pasty production lines, savoury kitchen, packing and palletization areas, order picking and packing.
  • Manage site safety compliance.
  • Ensured compliance to food safety requirements, product specifications and GMP adherence.
  • Developed cross-functional teams to foster collaboration and improved communication.
  • Boosted employee morale and productivity through effective leadership and motivational techniques.
  • Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
  • Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
  • Identified and resolved process and equipment issues to minimize production downtime.
  • Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
  • Enhanced safety standards with implementation of comprehensive safety training initiatives for all employees.
  • Analyzed production data and prepared reports for senior management.

Site Manager – (Flexible Packaging)

PPG (Pro Pac Group)
11.2021 - 07.2023
  • Managed a new site incorporating two businesses into one facility inclusive of operators, plant and equipment.
  • Developed new processes for safety, quality, productivity, CI, and maintenance.
  • Site duty holder for HSE, set up and facilitated HSE and JCC committees with reductions in near misses, injuries with zero LTI injuries.
  • Conduct safety investigations, RA's and JSA's are managed correctly.
  • Ensure that product meets customer specifications RFT, site GMP is maintained and deviations are escalated and investigated with corrective actions.
  • Implemented SQS using FSSC 22000 and 5S principles.
  • Participated in food safety audits FSSC-22000, HACCP.
  • Lead CI processes using lean best practice methodologies.
  • Ensured production OEE's are maximized with increased uptime and run speeds.
  • Investigated any extensive downtime using 5 why methodologies and implemented action plans.
  • Managed site budgets optimizing labour efficiencies based on weekly forecasting of production volumes.
  • Review production plans to optimize the plant efficiencies.
  • Prepare site CAPEX projects as needed.
  • Developed and implemented rosters, holiday planners and managed payroll discrepancies.
  • Developed and implemented team meeting boards, for daily standup meetings.
  • Conducted regular site meetings with team members, fostering open communication channels for efficient problem-solving and progress updates.
  • Managed all recruitment into site-based roles, interviewing, onboarding.
  • Managed all HR related issues with prompt response to disciplinary investigations, union and EBA management.
  • Organized site training, site training plans, matrixes.
  • Ensuring document control is up to date, SOP/OPL documentation aligns to tasks.
  • Conduct staff 1 on 1's, development plans and staff talent mapping.
  • Coach, support and develop teams across the departments using the GROW model technique.
  • Managed the site supply chain function including planning and scheduling, stock management, purchasing of site consumables, warehouse, distribution, and logistics.
  • Oversee site maintenance team, site maintenance plans, preventative maintenance, contractors, critical spare parts.
  • Responsible for building site maintenance and security.
  • Reduced safety incidents by conducting regular site inspections and enforcing strict adherence to safety protocols.
  • Created weekly and monthly reports and presentations for management team.
  • Coordinated site investigations, documented issues, and escalated to executive teams.
  • Evaluated employee performance and conveyed constructive feedback to improve skills.

Manufacturing Manager –

Lactalis
09.2018 - 11.2021
  • Managed 10 direct reports, production team leaders, line leaders plus 100 indirect line operators and casual pools.
  • Responsible for 1 x PET ESL HSF line, 3 x UHT Tetra pack HSF lines, 6 x fresh milk production lines, processing plant and equipment, dry goods warehouse, automated palletizing areas and distribution.
  • Managed and participated in site regulatory and internal audits.
  • Work with maintenance teams to identify and fix issues across departments reviewing actions to get plant issues rectified.
  • Management of SAP transactions, stock movements, work orders and batch management.
  • Delivering CAPEX and OPEX projects within expected time frames.
  • P&ID reviews, commissioning of new plant and equipment, looking for opportunities to deliver future cost improvements.
  • Maintain a working knowledge of EBA's, all company policies, procedures, practices.
  • Designed and implemented CI improvements across site implementing team KPI meeting boards, RCA 5 WHY processes and team engagement action boards.
  • Assisting in NPD initiatives to commercial production.
  • Ensured the effective management of environmental programs.
  • Coach and mentor reports, developed and implemented individual development plans, participated in talent mapping processes.
  • Lead / participate in the selection, recruitment, and training of site staff.
  • Improved production efficiency by streamlining manufacturing processes and implementing lean principles.
  • Increased output capacity with the optimization of equipment layout and workflow improvements.
  • Collaborated with cross-functional teams to ensure on-time delivery of products while maintaining high quality standards.
  • Implemented cost-saving measures by identifying areas of waste reduction and negotiating favorable contracts with suppliers.
  • Established performance metrics for staff members, enabling effective evaluation of individual contributions and overall team success.
  • Conducted root cause analysis investigations to identify areas for improvement in manufacturing processes, leading to increased efficiency and fewer defects.
  • Ensured compliance with safety regulations at all times, conducting regular inspections and promoting a culture of safe work practices among employees.
  • Optimized scheduling processes to maximize resource utilization while minimizing labor costs and overtime expenses.
  • Managed budget planning and forecasting activities for the manufacturing department, ensuring alignment with corporate financial goals while maintaining operational excellence.
  • Anticipated and addressed production problems, material shortages, equipment malfunctions, and unavoidable delays.
  • Made sure that products were produced on time and are of good quality.
  • Applied lean principles to improve workflow and quality and reduce waste.
  • Reviewed processing schedules and production orders concerning inventory requirements, staffing requirements, work procedures and duty assignments, considering budgetary limitations and time constraints.
  • Revitalized operational structures and procedures to successfully control turnover and waste, enhance output, and boost overall quality.
  • Conducted performance reviews each quarter, offering praise and recommendations for improvement.
  • Performed statistical analyses to gather data for operational and forecast needs.
  • Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
  • Trained in and implemented emergency response procedures to protect team members and property.

Plant Manager – (Paediatric Dairy Powder Plant)

Fonterra
05.2016 - 09.2018
  • Managed daily site operations inclusive of production areas, warehousing, distribution, utility services, environmental and formulation operations.
  • Managed 8 direct reports including team Leaders, production technologist, formulations managers and 90 + indirect reports.
  • Support the implementation of a safe work culture, managing compliance auditing, SOP reviews, safety observations, LOTO procedures, injury management, RTW plans and enforcing company policies and procedures.
  • Delivered Fonterra goals and cost saving initiatives as per agreed expectations.
  • Mentoring a high performance team across all departments, ensuring effective 1on1's , PIP plans, mid / end of year employee reviews.
  • Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
  • Boosted employee morale and productivity through effective leadership and motivational techniques.
  • Ensure food safety and product quality adherence and compliance with HACCP and GMP programs.
  • Assisting with implementation of NPD initiatives to commercial production.
  • Reduced downtime for maintenance by establishing a proactive preventive maintenance program.
  • Collaborated with engineering team to design new machinery, resulting in increased production capacity.
  • Championed sustainable practices throughout the facility, implementing waste reduction strategies and energy-efficient technologies.
  • Conducted thorough root cause analyses on production issues, identifying solutions for continuous improvement efforts.
  • Maximized plant safety through proactive strategies and well-structured training.
  • Provided direction and leadership to all levels of employees and managers.
  • Trained in and implemented emergency response procedures to protect team members and property.

Production Manager – (Canning, Bottle, and Kegging Lines)

Carlton & United Breweries
12.2014 - 05.2016
  • Manage daily operations for three production lines.
  • Oversee the daily duties of 12 direct reports including team leaders, planners, maintenance controllers and manufacturing development specialist and 60 + indirect reports.
  • Ensuring 100% conformance to safety, OH&S managing compliance auditing, SOP reviews, safety observations, LTCT procedures, injury management, RTW plans and company policies and procedures.
  • Mentoring a high-performance team across all production lines, ensuring effective 1on1's employee reviews, training programs and succession planning using CUB MDEV principles.
  • Ensure that all production quality standards are in place ensuring GMP, short interval checks and HACCP are audited and adhered to.
  • Report to SLT on plant performance and KPI trends for production lines and action plans for downtime.
  • Maintain factory operating efficiencies across all production lines investigating downtime causes and fixes.
  • Monitor macro extract loss and and production losses daily.
  • Identify ongoing improvement opportunities cost and plant efficiencies.
  • Champion MDEV strategic plans driving best practice utilizing 5S implementations by area, CPA, autonomous maintenance and learning and development plans.
  • Enhanced production efficiency by streamlining processes and implementing lean manufacturing techniques.
  • Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
  • Collaborated with cross-functional teams to ensure timely delivery of high-quality products according to customer requirements.
  • Conducted root cause analysis on production issues, devising corrective actions to prevent recurrence.
  • Implemented preventive maintenance programs for equipment, extending their lifespan and minimizing downtime due to malfunctions.
  • Fostered a culture of continuous improvement by encouraging open communication between team members and regularly soliciting feedback on operational procedures.

Logistics & Draught Production Manager

Carlton & United Breweries
10.2012 - 12.2014
  • Ensure safety of team on shift by auditing staff on job, effective communication of any safety issues and adhering to CUB lifesavers initiatives.
  • Team leadership of 12 direct reports and ensure the team is achieving KPIs.
  • Create a positive working environment with direct communication of information and goals to clarify expectations to all in the team.
  • Manage machine efficiencies (draught operations and palletizers) are running at highest capability and action any issues immediately.
  • Data reporting on multiple logistics functions daily.
  • Ensuring daily warehouse efficiencies (7.5 acres) – including minimizing stock loss, meeting KPI targets, monitoring warehouse capacities, stock picking for staging areas.
  • Immediate problem solving across any functional issues within the logistics team.
  • Improved team performance, morale, and the team's contribution to the wider business.
  • Implement change management adhering to SAB Miller or senior management changes across the business.
  • Implementation and continuous monitoring of MDEV initiatives and 5S areas.
  • Ensuring DIFOT distribution of products to all over Australia via a wide range of 3PL transport companies ensuring correct loading of product adhering to all COR regulations on and off site.
  • Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.
  • Conducted root cause analysis on production issues, devising corrective actions to prevent recurrence.
  • Managed internal operational standards and productivity targets.
  • Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
  • Scrutinized production output and identified areas for improvement.
  • Analyzed production data and prepared reports for senior management.

National Operations Manager

Salvo's Stores Salvation Army
06.2008 - 10.2012
  • Hold overall responsibility for all aspects of Operations for over 215 retail stores across Victoria, Tasmania.
  • Responsible for the operations budget and P&L including CAPEX projects.
  • Operational budget (excluding stock) of $6.5 m PA.
  • Charged with re-development of the Operations business resulting in a significant decrease in running costs and increase in productivity and efficiency.
  • Managed strategic planning coupled with continuous improvement initiatives.
  • Management of 80+ employees across various functions including managers, supervisors, administration, national call centre, warehouse, and truck drivers.
  • Effective management of over 20,000sqm of warehouse space.
  • Accountable for DIFOT and customer service / satisfaction.
  • KPI development, improvement, and adherence.
  • Assisting / mentoring the retail sector at operational/store level to maximise profits and ensure optimal end to end performance of the stores.
  • Manage inventory control including stocktake, purchased goods, WMS, distribution, and inwards goods.
  • Direct a fleet of 40+ trucks operating from multiple sites including fleet and system management.
  • Ensure compliance with OH&S requirements.
  • Export management including 3PL, contract negotiation, consultation with overseas clients, staff management.
  • Developed and executed strategic plans for business growth, resulting in expansion into new markets.
  • Established strong relationships with vendors and suppliers, negotiating favorable contracts and reducing procurement costs.
  • Managed budgets and financial reporting to ensure fiscal responsibility and cost-effective operations.
  • Oversaw the successful completion of numerous projects while maintaining strict deadlines and budget constraints.
  • Collaborated with cross-functional teams to achieve business goals, fostering a culture of teamwork and cooperation.
  • Improved customer satisfaction rates through enhanced communication strategies between departments.
  • Introduced new methods, practices, and systems to reduce turnaround time.
  • Built and maintained relationships with local vendors, suppliers and partners to maximize supply chain management.
  • Implemented business strategies, increasing revenue and effectively targeting new markets.

Education

High School Diploma -

Frankston High School
Frankston, VIC
12.1992

Skills

  • Safety Management
  • Resource Coordination
  • Team Building and Development
  • Lean Manufacturing Principles
  • Cost Control
  • Problem Solving
  • Plant and Warehouse Operations
  • Waste Reduction
  • Attention to Detail
  • Multitasking Abilities
  • Critical Thinking
  • Flexible and Adaptable

Training

  • Operation Timeline Project Management
  • Leading with Simplicity
  • Fundamentals of Packaging
  • Fundamentals of Leadership
  • Investment in Excellence
  • Stepping into Leadership
  • Essentials of Leadership
  • Four Quadrant Leadership
  • GMP management in implementation
  • OE/ Manufacturing way, 5S, lean manufacturing
  • FSSC 22000 training and management
  • HACCP certified.
  • Allianz Insurance Work Cover training
  • Environmental Awareness
  • Chief Fire warden and First Aid Trained
  • COR compliance trained.

References

Available on request

Timeline

Plant Manager – Bakery

Laurent Bakeries
07.2023 - 10.2023

Site Manager – (Flexible Packaging)

PPG (Pro Pac Group)
11.2021 - 07.2023

Manufacturing Manager –

Lactalis
09.2018 - 11.2021

Plant Manager – (Paediatric Dairy Powder Plant)

Fonterra
05.2016 - 09.2018

Production Manager – (Canning, Bottle, and Kegging Lines)

Carlton & United Breweries
12.2014 - 05.2016

Logistics & Draught Production Manager

Carlton & United Breweries
10.2012 - 12.2014

National Operations Manager

Salvo's Stores Salvation Army
06.2008 - 10.2012

High School Diploma -

Frankston High School

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