Patrick Lutta
Sydney,NSW
Summary
Adaptable and results-driven Quality Manager with over 16 years of experience in quality assurance, process improvement, and warranty management within heavy manufacturing, aviation, and fuel distribution industries. Certified Lead Auditor (ISO QMS 9001:2015) with extensive knowledge of mechanical and refrigeration systems. Proven track record of analyzing data to drive process improvements, collaborating with cross-functional teams to resolve warranty claims, and ensuring compliance with ISO standards. Recognized for delivering key quality initiatives that optimize resources and improve customer satisfaction. Proficient in Microsoft Office Suite, ERP systems, and industry-specific tools.
Overview
18
18
years of professional experience
1
1
Certification
Work History
Quality and Process Improvement Engineer
WEIR Minerals Australia
04.2024 - Current
- Exemplary Quality Assurance initiatives and customer engagement: led quality assurance initiatives for all pumps under manufacture by conducting regular inspections, collaborating with the Supplier Quality team, and resolving all customer complaints in a timely manner
- Leveraged my certifications in auditing to conduct regular inspections and audits to ensure compliance with ISO 9001; 2015 and AS/NZ standards
- Analyzed data to identify inefficiencies and provided recommendations to senior management, driving process improvements that increased operational efficiency by 20%
- Meticulous Process Improvement strategies to address high impact and repetitive issues leading to sick pumps which will give rise to cost savings and good timely service to our customers
- Re-engineered the entire Pump Assembly Process Map by introduction of a new criteria for sick issue classification for ease of analysis and follow up leading to root cause analysis
- Root cause analysis - implemented the Quality tracker within Pump Assembly shop to track and analyze repetitive and high impact sick issues and led in implementing 5Whys Root Cause Analysis (RCA) and track corrective and preventive actions to closure
- Reviewed all warranty claims by conducting thorough investigations and resolving all issues
- Evaluated new technologies and equipment upgrades to enhance overall process capabilities, ensuring market competitiveness.
- Provided technical assistance to production team when issues arose.
- Coordinated with suppliers to resolve raw material issues affecting production schedules.
- Optimized manufacturing processes by implementing continuous improvement initiatives and lean methodologies.
Senior Engineer - (Maintenance and Projects)
Vivo Energy Kenya Limited (Shell Licensee in Africa)
02.2020 - 04.2024
- Managed a team of 8 technicians, driving maintenance and troubleshooting activities for fuel distribution depots and commercial equipment, reducing equipment breakdowns by 25%
- Led cross-functional collaboration to resolve technical warranty claims and ensure compliance with company standards, resulting in a 30% reduction in incidents
- Supported warranty-related technical inquiries from internal and external stakeholders, providing solutions aligned with quality standards and customer satisfaction
- Developed and executed energy cost reduction initiatives, resulting in a 32% savings by installing solar PV panels at 20 commercial stations
- Oversaw the implementation of ISO 9001:2015 QMS compliance strategies, ensuring all operations met regulatory and industry requirements
Aviation Operations and Assistant Quality Systems Manager - ISO QMS
Vivo Energy Kenya Limited (Shell Licensee in Africa)
09.2012 - 01.2020
- Spearheaded ISO QMS compliance for the entire group and ensured that the company policies were up to date
- Ensured the depot operations were compliant with the company policy and regulations and consequently passed all Audits - (Customer, ISO QMS, International Compliance Inspections (JIG), IATA audits)
- Achieved Goal Zero throughout 7 years with 52,560 LTI (Lost Time Injury) free hours
- Managed the day-to-day depot operations - both Solus and JV (Joint Ventures) e.g
- Aircraft fueling operations, shift management, Fleet Management, equipment maintenance, and contractor management
- Provided HSSE Leadership in the Depot (Focal point for HSSE - Incident Investigation; HEMP (Hazards and Effects Management Process)
- Developed and managed a USD 4M department budget
- Optimized inventory levels and managed stock (Jet A-1 and Avgas thereby preventing shortages and excesses
- Recognized by the management for operational excellence and facilitation of the onboarding of 8 new customers
- Drafted subcontracts and contracts for HSE work and facilitated safety training for all on-boarded contractors
- Championed a high-performance safety culture through the training of 40 staff on aviation safety and compliance
Maintenance Engineer
Mumias Sugar Company
01.2008 - 08.2012
- Supported implementation of ISO QMS as a member of the steering committee through conducting internal audits and participation in external audits
- Performed overall maintenance planning of Sugar processing plant, machinery: Steam turbines, Low and High-pressure Water tube boilers, Diesel Engines, Air compressors, centrifugal machines, evaporators, vacuum pans, pumps, conveying systems, sugar driers, packaging plant, Water Treatment Plant (RO Plant)
- Steered a team of 10 in implementing maintenance schedules while performing root cause analysis on technical issues resulting in downtimes
- Delivered cost reductions of overall maintenance costs (spares and consumables) and utility costs (steam, power, compressed air, diesel fuel, bagasse fuel, water) by proposing additional modules on SAP for the section and collaborating with the procurement department on planning for the purchases of spares
- Developed and managed a USD 1M project budget
Management Trainee
Mumias Sugar Company
12.2006 - 12.2007
- Compiled technical reports (equipment specifications and design drawings), and performed modifications, testing, and maintenance of mechanical equipment
- Extensively trained in all departments of the Sugar Plant
Education
Certificate Training and Assessor -
Kenya Shell
01.2012
Bachelor of Science - Mechanical Engineering
Jomo Kenyatta University of Agriculture and Technology
07.2006
Skills
- Quality Management
- ISO 9001:2015
- Compliance Auditing
- Training and Assessment
- Internal Audits
- External Audits
- Warranty Management
- Data Gathering
- Data Analysis
- Technical Documentation
- Reporting
- Mechanical Systems
- Pumps
- Heating Systems
- Refrigeration Systems
- Pipelines
- Tanks
- Pressurized Vessels
- ERP Systems
- SAP
- AutoCAD
- Solid Works
- CMMS
- Leadership
- Collaboration
- Cross Functional Teams
- Lean Manufacturing
- Kaizen
Certification
- CEM (Certified Energy Manager), Association of Energy Engineers (AEE, USA), 10/01/17
- Member - Engineers Board of Kenya, B-B4722, 01/01/07
- Member - Project Management Institute (PMI), 07/01/22
- Practitioner- HEMP (Hazards & Effects Management Process), 08/01/14
- Trainer-Air BP Accredited Trainer, 05/01/16
- Practitioner- HAZOP (Hazards and Operability Study) Training, Vivo Energy (Shell Licensee in Africa), 01/01/20
- Authorized Inspector- Scaffold Inspection Program (SSCI), 03/01/15
- Internal Quality Auditor (ISO QMS), Kenya Bureau of Standards, 08/01/10
- Lead Auditor (ISO QMS 9001:2008), Kenya Bureau of Standards, 03/01/12
- Lead Auditor (ISO QMS 9001:2015), SGS, 02/01/18
- Trainer -Permit to Work (PTW) and Authorized Gas Testing, Vivo Energy (Shell Licensee), 12/01/14
Keyareasofexpertise
- Quality Management-ISO 9001:2015, compliance auditing
- Training and Assessment-Internal and external audits development and delivery
- Warranty Management-Ensuring corrective actions on defects, review claims and conduct investigations
- Data gathering and analysis
- Technical documentation and reporting
- Extensive knowledge on mechanical systems such as pumps, heating and refrigeration systems, pipelines, tanks, and pressurized vessels
- Mastery in ERP systems - SAP, AutoCAD, Solid Works, CMMS
- Leadership and collaboration with cross functional teams
- Extensive knowledge on Lean Manufacturing and Kaizen
Timeline
Quality and Process Improvement Engineer
WEIR Minerals Australia
04.2024 - Current
Senior Engineer - (Maintenance and Projects)
Vivo Energy Kenya Limited (Shell Licensee in Africa)
02.2020 - 04.2024
Aviation Operations and Assistant Quality Systems Manager - ISO QMS
Vivo Energy Kenya Limited (Shell Licensee in Africa)
09.2012 - 01.2020
Maintenance Engineer
Mumias Sugar Company
01.2008 - 08.2012
Management Trainee
Mumias Sugar Company
12.2006 - 12.2007
Bachelor of Science - Mechanical Engineering
Jomo Kenyatta University of Agriculture and Technology
Certificate Training and Assessor -
Kenya Shell
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