JACK RONGE
MANUFACTURING, OPERATIONAL EXCELLENCE, R&D INNOVATIONS AND PROJECT MANAGEMENT PROFESSIONAL
Nakuru,31
Summary
Manufacturing, Operational Excellence, R&D Innovations & Product Development & Project Management, across Multinational Tea Business Manufacturing and Operational Excellence Leader with over 15 years of experience driving quality transformation, process optimization, and innovation in manufacturing environments. A Chemist by training with deep expertise in analytical lab management, R&D, and production systems, skilled at turning technical insight into efficient, compliant, and scalable operations. Proven success in leading multi-site manufacturing projects, implementing World Class Manufacturing (WCM) principles, and delivering measurable improvements in productivity, cost, and product quality. Executed company-wide quality and manufacturing strategies, overseeing end-to-end operations from raw materials to finished product while ensuring GMP compliance and regulatory alignment. Recognized for embedding operational discipline, upgrading food safety and quality systems, and fostering a culture of continuous improvement and accountability across teams. A results-driven leader committed to building sustainable, high-performance manufacturing systems that translate strategy into excellence on the factory floor.
Overview
17
17
years of professional experience
Work History
Head of Future Technologies- Quality, R&D Innovations and Technology
Browns East Africa Plantations PLC
06.2024 - 10.2025
- SCOPE: Appointed to lead R&D innovation, Quality and technology functions across Browns tea estates and manufacturing sites in East Africa. Responsible for developing, implementing, and managing the company’s Quality Management System (QMS) to ensure compliance to the highest standards of safety, legality, and quality. The custodian of Innovation and manufacturing strategies that aligns to overall business objectives. Responsible for the End-to-end Innovations funnel and the deployment of products (5 M Kgs/Yr) for market penetration. Drives technologies (Analytical, mechanization, automation and digitization) that reduce costs, improve process quality, and deliver consumer-centric innovations. Oversee a team of 3 Managers and 20 indirect reports, while interfacing with critical external and internal stakeholders.
- Key Contributions & Achievements:
- 1. Innovation Strategy & Revenue Impact
- O Developed Innovation strategies that drive sales of nouveau items that unlock new frontier in liaison with sales and marketing. Manage the entire product lifecycle, from formulation and testing to implementation at manufacturing sites.
- O Led cross functional teams and commissioned the process Kibeho factory in Rwanda in 2024 and introduced new selling mark with 2M KGs/yr of high-quality products sold at premium.
- O Collaborated with sales and marketing teams to translate consumer insights and feedback into item mix improvement and new product development.
- 2. Future Technology, Automation & Digital Factory Deployment
- O Implemented Kenya’s first fully automated tea processing line, improving efficiency and output consistency.
- O Deployed field-based mechanization (e.g., mechanized weeding) to reduce labor costs and boost productivity.
- O Piloted digital monitoring tools to enhance traceability from leaf to pack.
- 3. Operational Excellence, Quality Assurance & FSQMS
- O Executed the company’s quality strategy and manage all aspects of operational quality control from RM to FG and served as the senior point of contact for all quality inquiries.
- O Provide strategic direction for the quality function and upgraded Food Safety and Quality Management Systems across all facilities, and ensured regulatory compliance and lead WCM Quality Pillar.
- O Achieved improved audit outcomes, regulatory and customer compliance scores. Led investigations of quality deviations, non-conformances, or incident and coordinated implementation of effective corrective and preventive actions.
- 4. Cross-Functional Collaboration & Governance
- O Built an agile innovation model bridging R&D, Marketing, Operations, and Quality to transform market intelligence, insights and feedback into scalable products that win in the marketplace.
- O Conducted competitor and sister company benchmarking and technology scanning to identify innovation opportunities that will deliver improvement projects. the collaboration initiatives forecasted to generate $7M in 2025 across all entities.
- O Co-led strategic reviews with senior leadership to align innovation with core business KPIs.
Research and Development Manager- Innovations
Lipton Teas and Infusions
06.2022 - 06.2024
- SCOPE: Led end-to-end innovations strategy and execution, introducing disruptive ideas and advanced technologies to product development across Lipton Teas and Infusions in Kenya, Tanzania and India. Oversaw R&D budgets, lab resources, and project timelines, balancing technical excellence with cost efficiency and commercial priorities.
- Key Contributions & Achievements:
- PRODUCT DEVELOPMENT
- 1. Product Innovation & Commercialization
- O Delivered award-winning “Cold Infusing Teas” generating €1.5M in new revenue.
- O Implemented a streamlined process for ideation, testing, and launch, reducing the time-to-market for new products by 20% e.g. Project Minion Ideation to commercial production in 8 months.
- O Secured IP and patents for novel processing methods and managed entire product lifecycle.
- 2. Technology & Automation Advancement
- O Procured, installed and commissioned Bolder Technology Line 2 doubling capacity to 3M Kgs/ year delivering increased revenue at reduced cost
- O Reduced process variability and improved scalability through lean automation.
- O Accelerated tech integration with minimal disruption to operations.
- 3. Time-to-Market & Innovation Culture
- O Reduced ideation-to-launch cycles by 20% through agile workflows.
- O Introduced structured innovation sprints involving cross-functional teams.
- O Fostered a culture of continuous improvement and experimentation.
- 4. Talent Development & Leadership
- O Mentored junior researchers, resulting in internal promotions.
- O Introduced peer learning sessions and collaborative prototyping labs.
- O Represented Lipton Kenya in global innovation forums.
R&D Manager- Innovations
Unilever Tea Kenya
11.2021 - 06.2022
- SCOPE: Managed innovation pipeline and aligned global strategies with local factory capabilities to optimize development and execution of product and process innovations. Led the end-to-end execution of a balanced portfolio of innovation projects through the IPM funnel to commercial launch. Acted as a technical advisor to UTEA factories, strengthening operational excellence and innovation integration on the factory floor. Built a high-performing R&D team through mentorship, training, and effective people management practices.
- Key Contributions & Achievements:
- 1. Successful Delivery of Innovation Project Portfolio
- O Ensured innovation projects aligned with both global R&D priorities and Unilever Tea Kenya’s business strategy, maximizing local relevance and global synergy.
- O Execution Excellence: Drove projects to completion within scope, budget, and timelines, using robust project management methodologies and coordination of multidisciplinary teams.
- O Commercialization Impact: Seamlessly transitioned new technologies and products from pilot scale to commercial production, enabling on-time market launches with clear business benefits.
- 2. Development and Commercialization of Novel Technologies
- O Product/Process Innovation: Led R&D in idea generation, technical specification development, and product trials, resulting in unique offerings with potential IP and market differentiation.
- O Factory Readiness: Coordinated with manufacturing to ensure readiness for scale-up, including commissioning, troubleshooting, and operator training for new technologies.
- O Consumer & Regulatory Compliance: Liaised with SEAC to ensure safety, compliance, and claims substantiation—protecting Unilever’s brand and legal interests.
- 3. Technical Support to Factories and Strategic Advisory Role
- O Cross-Functional Collaboration: Provided real-time support for issues such as quality troubleshooting, process optimization, and analytical services.
- O Specification Management: Developed and maintained robust product and process specifications to ensure consistent quality and customer satisfaction.
- O Capex & Business Case Development: Built strong business cases for investment in new projects and technologies, ensuring alignment with factory and business growth strategies.
- 4. Capability Building and Team Development
- O Leadership & Coaching: Supervised and mentored a team of over the R&D research assistants, enhancing both technical and project delivery capabilities.
- O Skill Advancement: Identified skills gaps (especially with new technologies) and implemented upskilling programs under tight timelines.
- O Culture of Innovation: Fostered a culture of curiosity, experimentation, and continuous improvement within the R&D function.
World Class Manufacturing Officer
Unilever Tea Kenya
05.2017 - 11.2021
- Pillar activities for loss eradication in manufacturing. Charged with developing site masterplans implementing, skill development, continuous improvement and cost-saving initiatives across the factories using World Class Manufacturing (WCM) principles for the 10 pillars (Safety, Cost, Quality, AM, PM, Focused Improvement, CSL, EEM, People Development and Environment.
- Key Contributions & Achievements:
- 1. WCM Strategy & Execution
- O Developed and Rolled out WCM masterplan, aligning to the broader company goals and achieved $1M+ in cost savings in 2018.
- O Leaf the FI pillar, drove zero based budgeting and led zero-loss analysis workshops and kaizen activities.
- O Implemented a robust metric tracking mechanism adhered to millstones and improved operational KPIs across all factories like 15% increase in throughput and productivity.
- 2. Performance Dashboards & Tracking
- O Introduced real-time KPI dashboards at shop-floor level.
- O Utilized data analysis and performance measures to identify and prioritize losses in production areas, applying rigorous root cause analysis, Cost Deployment and the Zero Loss concept to eliminate inefficiencies.
- O Installed WCM boards to enhanced visibility of savings pipeline and execution and fostered a culture of continuous improvement throughout the manufacturing process
- 3. Factory Governance Model
- O Implemented the Unilever factory governance model across 8 factories, creating a robust manufacturing foundation aligned with the company’s strategic goals. Standardized governance structures across the 8 factories.
- O Increased engagement of operators in problem-solving.
- O Linked WCM audits to factory incentive systems.
- 4. Training & Capability Building
- O Designed and executed training programs for different levels. Trained over 500 factory personnel on WCM principles.
- O Acted as the TPM coach for all the implementation pillars and developed in-house trainers and improvement champions.
- O Institutionalized lean thinking across teams.
Plant Manager- Chagaik Factory
Unilever Tea Kenya
09.2019 - 01.2020
- Specifications through process improvement, GMP certification, and quality transformation.
- Key Contributions & Achievements:
- 1. Production Planning & Innovation Delivery
- O Led the production team and played a pivotal role in the implementation of 5ME project Minerva aimed at delivering innovative products in 2019.
- O Implemented Good Manufacturing Practices (GMP) across all sections of the production shifts, resulting in improved process efficiency and product quality.
- O Monitored production KPIs and generated relevant reports.
- 2. Quality GMP & Process Compliance
- O Contributed to the development and production of high-quality products, which resulted in an incremental turnover of over 100,000 USD, earning recognition with the UTK Award.
- O Embedded GMP and HACCP across all production stages. Improved factory hygiene and reduced contamination risk.
- O Enhanced audit readiness and documentation culture, implemented rigorous sectional Quality Improvement plans
- 3. Stock Accuracy & Inventory Management
- O Monitored and validated stock and non-stock movements, ensuring accurate reconciliation of tea stocks in the factory, achieving nil loose teas for the first time in Chagaik resent history.
- O Managed factory stocks and dispatched products to the warehouse for sale
- O Released cash by reducing unwanted inventory
- 4. Factory Systems & Risk Management
- O Implemented QMS, OHSE, and RA protocols.
- O Conducted regular drills and audits for compliance.
- O Strengthened risk registers and escalation workflows.
Laboratory Services Supervisor
Unilever Tea Kenya
03.2012 - 05.2017
- Scope: Managed operations of the R&D Chemistry, Food and microbiology analytical labs that provide critical Materials & Applied Chemistry Testing and information for research and other business requirements.
- Key Contributions & Achievements:
- 1. Implementation of Laboratory Services & Revenue Generation
- O Delivered high-quality material testing services for various products and samples (Tea, Soil, Foliar, Fertilizer, Potable water, Effluent water) including external customers, resulting in profit of Ksh 1M in 2013.
- O Conducted a comprehensive nutritional survey for the 8,000 Ha Unilever Tea fields, leading to actionable insights that contributed to improved yields by 10% in 2016.
- O Implemented strategies based on data in optimizing soil and foliar conditions for tea cultivation and improved data-driven decision making in agronomy and tea breeding programs.
- 2. R&D Administration and Advisory
- O Implemented robust SHEQ system in the department ensuring nil safety incidents reported.
- O Participate in local and international ring tests, provide advisory reports to operations.
- O Received recognition in the form of company awards in 2016, for contributions to Strong Business and Safety improvements. Additionally, received the 2015 PRSK (Public Relations Society of Kenya) awards, showcasing excellence in public relations and communication within the industry.
Head of Chemistry and Food Laboratories
Kenya Bureau of Standards
10.2008 - 03.2012
- Scope: Established world-class analytical facility and oversaw analytical and food chemistry services for lake region ensuring compliance to standards. Conducted regulatory testing of food, beverages, soaps and dish washing detergents and other products.
- Key Contributions & Achievements:
- 1. Development of Lab Infrastructure & Revenue Generation
- A. Led procurement and setup of analytical equipment and chemicals
- B. Implemented lab manuals and procedures, safety and storage systems. Standardized reporting formats to KEBS standards
- C. Generated Ksh 3M in revenue for the fiscal year 2009/2010 through efficient lab operations and services. Increased efficiency driving average turnaround time improvement by 25%.
- 2. Accreditation, Scientific Representation & Policy Input
- A. Spearheaded the implementation of ISO 17025, ISO 22000, and ISO 9001 standards within the Chemistry and Food Labs.
- B. Trained staff in audit preparedness and internal QA. UKAS accreditation was acquired.
- C. Represented KEBS- LAR in National standards forums.
Education
Master of Science - Project Management
Liverpool John Moores University
UK 04.2001 -
Bachelor of Science - Chemistry (First Class Honors)
University of Nairobi
Nairobi, Kenya 04.2001 -
Skills
Proficient in ISO 22000, ISO 9001, and ISO 17025 management systems
Summary of Competencies
- Manufacturing, Quality & Food Safety Systems
- R&D and Product Innovation
- Lean Six Sigma & Continuous Improvement
- Technology & Automation Initiatives
- Scientific Regulatory Affairs and Technical leadership
- Operational Excellence
- Project Management
- Strategy Development & Execution
Awards & Recognition
LIPTON Global R&I Award (2023) – Cold Brew Commercialization, PRSK Award (2015) – Strategy Communication, Unilever Certificate of Achievement – UTK Strategy Delivery
References
Available upon request.
Timeline
Head of Future Technologies- Quality, R&D Innovations and Technology
Browns East Africa Plantations PLC
06.2024 - 10.2025
Research and Development Manager- Innovations
Lipton Teas and Infusions
06.2022 - 06.2024
R&D Manager- Innovations
Unilever Tea Kenya
11.2021 - 06.2022
Plant Manager- Chagaik Factory
Unilever Tea Kenya
09.2019 - 01.2020
World Class Manufacturing Officer
Unilever Tea Kenya
05.2017 - 11.2021
Laboratory Services Supervisor
Unilever Tea Kenya
03.2012 - 05.2017
Head of Chemistry and Food Laboratories
Kenya Bureau of Standards
10.2008 - 03.2012
Master of Science - Project Management
Liverpool John Moores University
04.2001 -
Bachelor of Science - Chemistry (First Class Honors)
University of Nairobi
04.2001 -