Plant Manager
Sunbulah Group
Total years of experience :5 years, 1 Months
- Responsible for the overall operations of the factory including the Production, Processes, Maintenance of equipment, Safety of work place and Quality of products .
- Responsible for the factory efficiency and improvement processes of the production lines and resolving operational conflicts .
- Responsible to set the factory quality and hygiene standards in liaison with Global business units to deliver the state-of-art facility and efficient operational methods .
- Reviewing Key Performance Indicators, identifying trends and formulating action plans to achieve targets .
- Review replenishment and ordering processes and systems and identify opportunities to optimize performance.
- Analyze the level and impact of process errors within Ordering on availability, stockholding and agree action plans to improve.
- Manage promotion, seasonal, holiday ordering including new range (minor and major change) ordering.
Joined as Materials Supply Management Department Manager, and charted an impressive growth curve through exceptional performance to merit promotion to Plant Initiatives and Projects Management Department Manager.
Designation Chronology:
• Feb 2013 - Present: Plant Initiatives and Projects Management Department Manager
• Sep 2011 - Feb 2013: Production Manager
• Oct 2010 - Sep 2011: MSM and Planning Departments Manager
• Sep 2009 - Sep 2011: Material Supply Management and Logistics Manager
Highlights:
• Played a key role in delivering all master plan projects with ZERO over spending and above 99% spending accuracy for budget of two digits Million SAR.
• Instrumental in developing a global scope of powder material blending project, which has been bestowed with an award globally and rolled out in Europe and USA plants.
• Efficiently accomplished 100% ISU (Instantaneous Start Up) in all initiatives and projects executed in the site for Pampers and forever production lines.
• Effectively reduced the planned downtime for the biggest project in the site from 10.5 days to 8 days average.
• Successfully carried out a regional VSM for commercial and technical initiative cycle recognizing all losses in initiative cycle and accordingly facilitated to reduce the initiative lead time from 24 weeks to 17 weeks, which is equal to 30% time reduction.
• Pioneered in reducing annual electrical bill by 500, 000 SAR by enhanced utilization of energy resources and various power saving projects.
Key Responsibilities:
• Formulating a master plan in accordance with company strategies, thus aiding the team by analyzing required skills and training to maintain smooth workflow.
• Spearheading and monitoring projects module of three departments encompassing construction, projects and initiatives along with utility department, whilst ensuring strict adherence to organizational policies and procedures.
• Foreseeing the annual initiatives and projects budget for seamless functioning of activities leading to optimal growth chart of the organization.
• Conducting supplier evaluation through purchasing, and working on the estimation of forecasted projects to verify suppliers’ capacity, ensuring better functioning in an efficient and effective manner.
• Working in close collaboration with the purchasing department pertaining to the qualification process for new suppliers to consistently chart out short and long term strategic goals with corresponding milestones.
• Instrumental in developing the cost estimation for all initiatives and projects, thereby managing the supplier bidding in coordination with the purchasing department to monitor project’s cost and budget opening.
• Accountable for delivering all the projects within specified time limit and cost, and ensuring that they are handed over in accordance with desired quality standards.
• Managing all new initiatives from both commercial and technical aspects to achieve the target launch date for new products.
• Instrumental in designing and implementing strategies to start up the project, enabling attainment of objectives, including selection and motivating of manpower to deliver the project within established time/budget.
• Administering the plant readiness review for each project to recognize whether the project is technical, commercial or construction in sync with corporate guidelines.
• Steering the start-up team to perform the commissioning, qualification and verification process execution.
• Formulating roll-out plan for the technical projects pertaining to obtaining all learning from the previous lines, and accordingly executing the same methodically in the roll-out plant resulting in maximized revenue.
• Keeping abreast of latest technological advancements and utilizing the potential of the same, to respond to the distinctive needs of the organization.
Highlights:
• Played a pivotal role in enhancing the reliability by 3.5% augmentation all the way through working on numerous loss analysis actions.
• Instrumental in reducing the number of daily unplanned stops by 60%, by focusing on team capabilities.
• Efficiently reduced the scrap by 0.5% by minimizing and controlling the variability in the critical processes.
Key Responsibilities:
• Developed and recommended design/process approaches necessary to meet production requirements in accordance with quality assurance and quality control procedures.
• Accountable for the overall operations of the production line by steering both operational and support teams to deliver the targets for several important factors to ensure that the company is winning in the market in terms of price and cost design.
• Influential in devising a monthly and weekly maintenance plan, whilst monitoring the overall maintenance budget to impact the production cost certainly in accordance with company standards.
• Served as a back-up leader for the E&T Pillar (education and training) as a part of IWS (integrated work system) contribution for seamless functioning of activities leading to optimal growth chart of the organization.
• Conducted periodic maintenance check of all production equipment and devised plans for smooth execution of production processes in accordance with daily/monthly production plans and schedule.
• Arranged regular meetings with the maintenance team to keep them updated regarding production activities; confirmed procedural adherence and provided recommendations for prompt remediation of unforeseen problems in production.
• Reviewed, analyzed periodic production reports, initiated corrective actions and spearheaded programs for quality improvement and manpower planning.
Highlights:
• Successfully merged both MSM and the planning departments in October 2010 to facilitate the MSM team and to develop the performance of the upstream supply chain.
• Played a cardinal role in condensing the raw and pack material inventory by 25% and accordingly boost up the cash flow by 9 million dollars.
• Successfully managed to implement the initiatives with ZERO remnants due to phase in phase out management.
• Attained benchmark results in UPI (unproductive inventory) with ZERO% in Red Bucket.
Key Responsibilities:
• Accountable for designing the master plan and accordingly aided the team to deliver the master plan by evaluating the requisite skills and training for assured operational excellence.
• Liable for monitoring the raw and pack materials planning department as an organizational change to facilitate the MSM team to be more effective and efficient in workflow execution.
• Oversaw the material supply process in close coordination with the planning team to arrange all necessary materials available on site and accordingly supervised the same to keep all KPIs on target inclusive of inventory level, DFC and CFR.
• Monitored inventory of materials, spare parts and equipment, thus analyzed the inventory buckets and reduced the opportunities to increase the cash flow along with auditing usage and authorizing orders to ensure continual production with minimal idle stock.
• Formulated effective performance management strategies by identifying areas of improvement and implementing measures to enhance performance level of the employees.
• Spearheaded the whole gamut of operational processes for the 3PLs with due relevance to company policies and procedures, consequently evaluated latest technologies to steer fulfillment performance targets.
Highlights:
• Pioneered in reducing the SCT time by 25%, by means of utilizing the right tools comprising of SMI, VSM, and UPI.
• Instrumental in deploying SLEA (service level execution agreement) and its update tracking system at 100%.
• Played a key role in setting up new system named SMI applying the concept of supplier managed inventory.
• Successfully maintained the SSP (supplier schedule performance) over 90%.
• Efficiently condensed the scrap material due to logistic damages and material handling by 85%, through executing numerous JVC (joint value creation) projects in synchronization with suppliers and forwarders.
• Proficiently attained total saving projects of 3 million dollars over two years.
Key Responsibilities:
• Maintained lucrative business relations with suppliers and accordingly built the potential internally in SNO and externally with the suppliers to systemize and simplify all work processes to enhance proper flow of work.
• Instrumental in portraying the strategy for upstream supply chain to develop performance, thereby implemented saving projects, reduced the supply chain time and lastly amplified cash flow by diminishing the inventory level.
• Responsible to symbolize the plant with the central buyer in the sourcing process during monthly regional allocation management meeting along with functioning with the regional team on strategic supply for better functioning.
• Effectively worked on the optimization of supply chain through building the capabilities in the upstream side to deliver the savings by means of zero loss mentality and joint value creation.
• Liable for implementing logistics strategies pertaining to INCOTERMs, carriers, custom clearing agencies and emergency backup plans aligned with organizational principles.
• Efficiently managed the lead process of documenting and tracking joint operating anticipation in close coordination with suppliers in various areas comprising of planning, delivery and inventory to guarantee supply chain consistency.
• Effectively escorted an annual supply chain loss analysis along with monthly supply chain saving tracking to ensure smooth working in an efficient way.
• Directed supplier logistics qualification whenever new supplier is being introduced to the site and accordingly actively participated in supplier capability assessment to make out new supplier’s potential.
• Led the coordination and qualification of changes in shipping lines / incoterms to chart a rising business curve for company services.
• Instrumental in developing/tracking supplier and logistical defects on inbound deliveries vs. total deliveries/month to enrich their competencies for achieving business goals.
• Prioritized efficient supply chains, thus, establishing new chains while keeping close tabs on market dynamics and trends.
Previous Professional Experiences:
• Sep 2007 - Sep2009: Instruments and Control Engineer with Saline Water Conversion Corporation (SWCC) - Shoaiba Plant, Jeddah, Saudi Arabia