Emile Muller
Operations Manager
Brisbane,QLD
Summary
Operations Leader and Certified Project Manager with 20+ years of international experience across FMCG, food, beverage, packaging, and recycling industries. Renowned for delivering transformation through Lean Six Sigma, TPM, TRACC, IWS, and Continuous Improvement methodologies. I bring proven expertise in managing full P&L accountability, embedding HACCP/GMP and ISO 9001, 14001, 45001 compliance, and leading WHS governance across large-scale sites. Throughout my career, I have been fully involved in plant installations, line upgrades, and process reconfigurations, ensuring projects are delivered on time, within budget, and in alignment with regulatory and safety standards. At T&G Global, I achieved a 40% uplift in OEE (1.4M apples per day) through Lean Six Sigma and CI coaching, while managing $18M OPEX and a workforce of 243. At One Pure International, I transformed a $4M loss into $1.3M profit by improving data-driven planning, stabilising procurement, and embedding SOPs and training. I have a strong record of capital project delivery alongside BAU, balancing innovation with operational reliability. Recognised as a firm-but-fair leader, I build high-performing teams, foster accountability, and drive cultural transformation by empowering staff at all levels. With deep technical knowledge and strategic foresight, I consistently deliver operational excellence, financial performance, and sustainable growth.
Overview
21
21
years of professional experience
Work History
Packhouse Operations Manager
T&G Global
12.2024 - 01.2025
- Company Overview: T&G Global is one of New Zealand's largest fresh produce companies. The Packhouse in Whakatu Hastings New Zealand is one of the largest and most modern apple packhouses in the Southern Hemisphere. Exporting their Envy Brand apples to over 60 countries worldwide. The company operates large-scale orchards and the world class packhouse is designed with a strong focus on global supply chain integration.
- Newly created transformation role with a mandate to optimise OEEs, analyse where further improvements could be made to processes and equipment, and to elevate team culture.
- Initiated review of opportunities for future capital projects to enhance capability and maximise throughput.
- Hold full accountability for $18M OPEX, driving world-class performance using Lean Six Sigma and Continuous Improvement (CI) principles.
- Provide leadership to an overall team of 243 with 23 direct reports.
- Facilitate monthly health and safety meetings and weekly FIT production meetings, as well as regular standups and other meetings.
- Hold monthly bilateral meetings with direct reports.
- Engage regularly with apple growers and play a key role in implementing CI across the business.
- Achieved 40% improvement in OEE (improvement of 1.4M apples per day) through improved training, processes and documentation of procedures and by instilling 'what good looks and feels like.'
- Delivered consistency and predictability in throughput, analysing maximum sustainable line speeds and enabled 90% continuous throughput of 3,500 apples per minute across 10 rapid lanes and 14 manual lanes.
- Ensured continued access to high-value markets through a focus on quality, identifying ideal wash speeds and nozzle pressures to provide the highest quality product.
- Refocused the team toward optimal outcomes and drove consistent completion of daily, weekly, and monthly activities through ongoing CI coaching and the Leader Standard Work program.
- Overcame strong cultural resistance to transform production workflows, working with a core group of staff volunteers to design and run scenarios, gather information, and prove the concept, then implemented changes that have led to greater efficiency while maintaining quality standards.
- Coordinated logistics and inventory management across multiple distribution centres.
- Developed training programs for staff to enhance operational performance.
- Implemented process improvements to streamline workflow and reduce waste.
- Monitored supply chain activities to maintain optimal stock levels and delivery schedules.
- Collaborated with cross-functional teams to resolve operational challenges effectively.
- Analysed operational data to identify trends and inform decision-making processes.
- Supervised the day-to-day workflow of employees to maximise productivity and maintain quality standards.
- Directed day-to-day operations by spearheading the implementation of short-term and long-term strategies to achieve business plan and profitability goals.
- Built strong operational teams to meet process and production demands.
- Managed staffing needs through recruitment, selection, onboarding and training, disciplinary action as necessary.
- Coordinated with other departments, including sales, marketing, finance, and human resources. To ensure efficient operations.
- Collaborated with the management team on long-term strategic planning initiatives for the organisation.
- Analysed data from daily reports to identify trends in production performance metrics.
- Improved morale and management communication by creating employee recognition and rewards practices.
- Oversaw financial management, budget management, accounting and payroll activities.
- Aided senior leadership during the executive decision-making process by generating daily reports to recommend corrective actions and improvements.
- Performed cost analysis for various projects to determine budget requirements.
- Formed and sustained strategic relationships with clients.
- T&G Global is one of New Zealand's largest fresh produce companies. The Packhouse in Whakatu Hastings New Zealand is one of the largest and most modern apple packhouses in the Southern Hemisphere. Exporting their Envy Brand apples to over 60 countries worldwide. The company operates large-scale orchards and the world class packhouse is designed with a strong focus on global supply chain integration.
Operations & Manufacturing Manager
One Pure International
07.2022 - 12.2024
- Company Overview: One Pure is a New Zealand-based premium water bottling company, producing and exporting still and sparkling mineral water to Asian and Pacific markets.
- Transformed operations, generating $1.3M profit from prior ~$4M loss via enhanced data collection and planning.
- Designed cost-effective operational systems to ensure production quality specifications were met.
- Managed manufacturing budget, overseeing OPEX of $3-4M and CAPEX of $1.5-7M for upgrades, with revenue of $10-15M.
- Established raw material procurement requirements using sales and production data for effective sourcing.
- Determined production schedules to maximise capacity and efficiency within budget constraints.
- Oversaw procurement and supplier communications to achieve production objectives efficiently.
- Led a team of 23, conducting daily stand-up meetings and facilitating weekly training sessions.
- Implemented safety protocols to enhance workplace safety standards and compliance.
- One Pure is a New Zealand-based premium water bottling company, producing and exporting still and sparkling mineral water to Asian and Pacific markets.
High Performance Manager
Freeze Dried Foods
06.2021 - 07.2022
- Company Overview: Freeze Dried Foods NZ is New Zealand's largest freeze-drying facility, producing freeze-dried Pet Food ingredients and consumer-ready products for export markets, including snacks, dairy, and fruit.
- Engaged with a mandate to improve plant throughputs for an already-thriving business.
- Developed and administered the manufacturing budget with an OPEX of $5.7M.
- Optimised operational systems to ensure cost-effective production and high-quality product.
- Determined production schedules and oversaw daily/weekly/ monthly raw material procurement and supplier communication.
- Reviewed manufacturing operations and made recommendations relating to systems and capital expenditure planning.
- Established and maintained daily reporting mechanisms across manufacturing and maintenance.
- Led seven direct reports and 53 indirect reports, plus five indirect engineering reports.
- Actively involved in production scheduling, maintenance planning, raw material scheduling, freezer store planning, and FIFO planning and control.
- Improved throughputs by 38% while reducing downtime and costs through deep-dive analysis of customer needs, finding efficiencies, and optimising time on plant, thus reducing runout times between customers.
- Freeze Dried Foods NZ is New Zealand's largest freeze-drying facility, producing freeze-dried Pet Food ingredients and consumer-ready products for export markets, including snacks, dairy, and fruit.
Site & Operations Manager
The Apple Press
07.2018 - 05.2021
- Company Overview: The Apple Press is a Hawke's Bay start-up producing premium apple juices from local fruit, including unique single-variety juices and contract bottling for Fonterra. Products are exported to Australia, Japan, China and other Asian countries, and stocked in New Zealand supermarkets.
- Hired due to extensive (10+ years) experience in PET bottle blowing and UHT plant operations with a mandate to optimise the filling line and create a sustainable manufacturing process that would address ongoing losses arising from poor production planning and lack of understanding of the UHT sterilisation process.
- Owned full accountability for $3.2M OPEX, and $1M CAPEX and maintenance budget.
- Embedded LEAN manufacturing principles to reduce production costs, minimise wastage, lower the cost of quality issues and increase productivity.
- Led development of and provision of continuous enhancements across food safety, quality, production and EHS processes.
- Managed a team of 12 indirect reports and eight direct reports.
- Worked closely with the engineering and maintenance teams to ensure the plant was well maintained to deliver optimal outputs.
- Assumed the responsibilities of PCBU and championed Health and Safety practices.
- Member of the senior leadership team, attending monthly board meetings and planning meetings.
- Reduced downtime and work stoppages between runs by 50% via Lean and Six Sigma continuous improvement practices that accelerated batching and production schedules.
- The Apple Press is a Hawke's Bay start-up producing premium apple juices from local fruit, including unique single-variety juices and contract bottling for Fonterra. Products are exported to Australia, Japan, China and other Asian countries, and stocked in New Zealand supermarkets.
Production Manager
Invictus Dairies
01.2017 - 01.2018
- Company Overview: Invictus Dairies specialised in producing sweetened flavoured milk, almond milk, UHT milk, and fruit juices for New Zealand and Asian export markets.
- Immigrated to New Zealand from South Africa to transform entrenched culture and optimise a factory producing various sweetened flavoured milk, almond milk, UHT milk, and fruit juices.
- Monitored all aspects of production, distribution, and sales.
- Identified areas for improvement and led development of key enhancement projects, managing financial performance and mentoring/leading a large team of 74 staff.
- Coached staff in batching processes and procedures maintaining quality compliance.
- Liaised with other business departments such as logistics and sales teams to support the delivery of strategic priorities and project objectives.
- Negotiated and secured a 3PL bottling agreement with Lewis Road Creamery for their 250ml range through a focus on showcasing operational excellence and optimized batching and run schedules.
- Transformed the team, addressing morale issues and entrenched attitudes to build a high-performing and positive culture focused on achieving enterprise results.
- Established a team based on diversity and inclusivity, which saw 27 staff of various ethnic groups across the workforce.
- Invictus Dairies specialised in producing sweetened flavoured milk, almond milk, UHT milk, and fruit juices for New Zealand and Asian export markets.
Operations Manufacturing Manager
MPXtruders
01.2012 - 12.2016
- Company Overview: South Africa
- Innovation and building role to establish a dry PET recycling plant.
- Led the development, implementation, and management of the business plan, strategic initiatives, sales strategy, and annual budget.
- Held full P&L accountability with a focus on establishing the business, developing a sales pipeline, and securing major accounts.
- Managed the human resources function such as recruitment, onboarding, training, performance management and leadership training.
- Provided leadership to a culturally diverse 47-person team.
- Worked closely with the client to identify requirements and manage the development of custom equipment.
- Established the business and built a strong pipeline of clientele, initiating partnerships with large plastic container manufacturers Nampak and Zibo Containers.
- Generated a new revenue stream by coaching and training non-profit organisations in collecting recyclables from schools as a reduce/recycle/reuse project.
- South Africa
Operations & Manufacturing Manager
Enviroserv Waste Management
01.2010 - 01.2012
- Company Overview: South Africa
- Headhunted by a waste-collection service to build an in-house plastics recycling function to capture value that had previously been owned by outside recycling services.
- Led business planning activities for new waste management streams, including creating new recycling collection opportunities for smaller businesses.
- Oversaw all aspects of people and culture, including capability development, cultural change, and performance management.
- Created a work charter and team charter in collaboration with teams as best practice guide and agreements.
- Successfully established in-house recycling capability by leading the acquisition of a fully-equipped plastic recycling facility, integrating the business, and continuing BAU under new management.
- Created a $12M revenue stream by finding alternate uses for waste, including visiting vineyards in the Western and Southern Cape and setting up supply chain of recyclable plastics from used irrigation pipes, and manufacturing roof tiles from waste plastics and glass.
- South Africa
Site/Plant & Manufacturing Manager
Nampak Liquid Packaging
01.2004 - 01.2010
- Company Overview: South Africa
- Held complete oversight of the production team and $86M budget with accountability for overall performance of the plant.
- Planned, coordinated, and managed all aspects of production, including asset management, maintenance, quality control testing, and logistics.
- Managed turnkey filling stations and bottle manufacturing equipment on customer sites, including maintenance.
- Led multicultural teams and fostered continuous improvement and sustainability through team support and collaboration with all stakeholders.
- Built strong relationships with internal and external stakeholders, including serving as the escalation manager for customers.
- Maintained relationships with 3PL Logistics provider and optimised the domestic freight network.
- Identified a new revenue stream, securing investment to procure unsold wine from a local vineyard and selling under a new brand in PET bottles.
- Future-proofed the business and created a leadership pipeline by effectively implementing staff development opportunities.
- South Africa
Education
Professional Project Management - Project Management
PMI International
12.2024
Advanced Business Management Certificate - Business Administration And Management
Henley Business School of London
11.1996
Logistics & Procurement Management - Procurement Management
Technikon Witwatersrand
12.1989
Industrial Labour Relations - Human Resources Management
Technikon Witwatersrand
12.1988
LEAN Manufacturing Principles - Manufacturing OEE Improvement
Technikon Witwatersrand
06.1988
Financial Administration - undefined
Technikon Witwatersrand
11.1987
Production Management - undefined
Technikon Witwatersrand
06.1987
Advanced Sales & Negotiation Skills - undefined
Technikon Witwatersrand
06.1987
Skills
- Food safety compliance
- Operational efficiency
- Continuous improvement
- Data analysis
- Inventory management
- Policy implementation
- Supply chain logistics
- Labor relations
- P&L management
- Financial expertise
- SAP proficiency
- Production management
- Contract negotiation
- Business intelligence
- Strategic development
- Health and safety compliance
- Regulatory compliance
- Lean manufacturing and design
- Sales expertise
- Cross-functional collaboration
- Lean Six Sigma methodology
- Cultural transformation initiatives
- Project management and cost control strategies
- Workforce leadership
Accomplishments
- Achieved a 43% improvement in OEE for T&G Global.
- Overcame embedded change resistance through the creation of committees.
- Turned One Pure International from loss to profit.
- Improved freeze-dried foods' throughput by 38%.
- Reduced the Apple Press' downtime between runs by 50%.
Daily Focus Snapshot - Process Ci Leadership
- Morning Kick-off & Alignment
- Process Optimisation
- Standardisation & Training
- Technical Support & Problem Solving
- Collaboration & Innovation
- Continuous Improvement Culture
- Performance Review & Strategy
Professional Development Certifications
- Prince2 Foundation Certification Training
- Advanced Business Management Certificate
- PMP Qualified Project Management
- Production Management
- Advanced Sales & Negotiation
- Financial Administration
- LEAN Manufacturing Principles
- Industrial Labour Relations
- Logistics & Procurement Management
Languages
English
Bilingual or Proficient (C2)
Timeline
Packhouse Operations Manager
T&G Global
12.2024 - 01.2025
Operations & Manufacturing Manager
One Pure International
07.2022 - 12.2024
High Performance Manager
Freeze Dried Foods
06.2021 - 07.2022
Site & Operations Manager
The Apple Press
07.2018 - 05.2021
Production Manager
Invictus Dairies
01.2017 - 01.2018
Operations Manufacturing Manager
MPXtruders
01.2012 - 12.2016
Operations & Manufacturing Manager
Enviroserv Waste Management
01.2010 - 01.2012
Site/Plant & Manufacturing Manager
Nampak Liquid Packaging
01.2004 - 01.2010
Professional Project Management - Project Management
PMI International
Advanced Business Management Certificate - Business Administration And Management
Henley Business School of London
Logistics & Procurement Management - Procurement Management
Technikon Witwatersrand
Industrial Labour Relations - Human Resources Management
Technikon Witwatersrand
LEAN Manufacturing Principles - Manufacturing OEE Improvement
Technikon Witwatersrand
Financial Administration - undefined
Technikon Witwatersrand
Production Management - undefined
Technikon Witwatersrand
Advanced Sales & Negotiation Skills - undefined
Technikon Witwatersrand