Head Of Production
SADAFCO
مجموع سنوات الخبرة :19 years, 10 أشهر
Lead the production team from mixing over processing to filling team in accordance with sadafco standards and international best practices to achieve production output in the most cost effective and efficient way.
Delivery of targeted Financial, Service and Quality performance results, through leadership and development of the Management team. Drive the continuous improvement process to achieve gains in efficiency and quality . Co-ordinate with necessary departments regarding safety, expansion, quality, projects and NPD.
Responsible for leading and coaching the Production Plant Team to deliver daily & strategic performance and continuous improvement as part of NFIC Site and contribute to Group Operations, including the day to day leadership of Plant.
Responsible for Health and Safety standards compliance in the department
Actively participate in developing and implementing the Site and Department Health and Safety Business Plans
As a Safety Leader, role model a “Safety First” approach by ensuring all employees, contractors and visitors understand and adhere to the NFIC safety policies, rules and safe work practices
Ensure H&S performance objectives are assigned to individuals and monitor H&S performance and compliance
Ensuring Quality standards for the products are met:
Demonstrate and promote a proactive commitment to product safety and compliance
Compliance to and maintenance of the Risk Management Plan (RMP) and all elements of this including pest, pathogen, heat treatment (ELLAB), water management and CCP’s
Compliance to and maintenance of an effective approved HACCP plan, ensure all CCP’s are managed accordingly
Ensure annual reviews of all quality manuals, RMP & HACCP are completed
Responsible for business sustainability
Identify capital projects that provide sustainable revenue or eliminate waste and ensure efficient implementation
Contribute to the development of the Asset Management Plan
Ensure wider Plant Team involvement in capital projects to optimize Plant maintainability
Responsible for improving Productivity
Ensure the Plant has a detailed loss and waste analysis in place (based on OEE) and structured data-driven and Team-based continuous improvement process
Ensure efficient and effective operation of all processes within control to achieve Key Performance Indicators (KPIs) in Company Business Plan/Objectives
Ensure production of the correct specifications of products is achieved on time and in full (DIFOT)
Responsible for planning People Development
Maintain locals percentage to enable Business meets its localization program and targets
Develop effective succession and recruitment plans to ensure a depth of knowledge and leadership within the Plant for seamless transition of key roles
Foster a learning and sharing culture between Plants, Support Services and other Business units
Ensuring Employee Performance objectives and development plans are implemented and reviewed quarterly for all direct reports and ensuring training and competency in delivering staff assessments
Manage the plant ensuring production volume targets are met while ensuring that safety, quality, service and cost targets are achieved. Ensure that staffs with the necessary skills are trained and available to run the plant. Drive the continuous improvement process to achieve gains in efficiency and quality. Co-ordinate with necessary departments regarding safety, human resources expansion, quality, new product development
Ensuring Health and Safety standards are met in the department:
Ensure Plant H&S programmes are in place and agreed with H&S manager. Agreed H&S audits, risk assessments, H&S initiatives are timely done and within H&S standards.
Effective Risk assessments are carried out for the complete area and equipments along with timely completion of corrective actions
Zero accidents
Ensuring products produced met the required Quality standards:
Ensuring right first time release of the product
Ensuring zero dumped material
Targeting zero tolerance for the non conformance product and Less than budgeted CPM
Maintaining AIBI score >850
Ensuring meeting the Customer demand:
Monitor stock levels daily/weekly to ensure market is supplied but not over stocked
Ensuring Customer service agreement (CSA) target is achieved
Understanding of potential market sales verses capacity and address capacity constraints to meet the demand
Optimize production plan to improve OEE and deliver production plan requirements
Actively involved in implementation of lean management initiatives to arrest the Cost:
Ensuring LIP for ingredients, packaging well under budget as well as labor cost under control
Carry out loss and waste analysis, identify top improvement projects and implement
Identify and address top LIP issues using structured problem solving tools
Ensure that budget is achieved and reduction of LIP and rejections is put to a minimal thus achieving consistent product yield optimization ultimately minimizing production cost.
Leading the effective utilization of tools to enhance Productivity
Productivity Improvements using Structured problem solving approach.
Put in place plan to progressively increase OEE by 5% every year
Leading the People Development plan within the department
Hold effective induction programmes for all new starts
Introduce daily line meeting with operatives to review line performance and nurture engagement
Draw up and implement an effective localization programme to deliver company targets
Ensure coordination with Training & Development of staff is done ensuring need analyses are carried out and ITP’s are executed promptly in accordance to training calendar.
Coordinate, facilitate and drive operational excellence initiatives in line with the Business manufacturing strategy
Leading implementation of Lean Management initiatives
Leading the Loss and Waste exercise in order to identify the waste in the process, carrying out speed profile study to identify bottlenecks, value the opportunities followed by prioritizing and action plan to reduce the losses
Key representative for implementing Target savings activities
Leading CIP optimization activities viz CIP time reduction, CIP regime optimization, chemical conc. reduction
Implementation and review of process confirmation checklist and control charts in order to have more focus on the operation by the manufacturing team
Leading drain losses reduction projects in order to reduce the waste in drain
Responsible for optimizing the process as well as increase in the current production volume by optimizing the production plan
Implemented Structured problem solving exercise using 5 whys, 5S, DMAIC, PDCA, SUTR and A3 so that the root cause is identified and proper corrective and preventive action implemented in place
Assisting production Managers in developing and reviewing pictorial SOPs
Analyze the need and purpose of each production set point responsible for driving the process line and drawing out the optimum requirement
Continually update the process and planning constraints and challenging continually for getting maximum benefits
Creation of cause-effect library for process related issues for supporting production, quality, engineering and other related departments towards quickly solving the product-process issues
Implement "Key performance indicators" monitoring chart for each line to monitor critical production parameters against the standards/limits
Dealing with suppliers to get the technical inputs for process and CIP
Optimization of the production parameters to have consistent quality products produced across all production lines
Optimization of ingredient usage to have efficient use of ingredients towards achieving targeted specifications
Preparation and maintenance of guiding rules for production planning, processing and cleaning conditions
Implemented the concept of Customer service agreement (CSA) in the plant
Coordinating with cross functional team viz production, quality, TRD, CIT to develop the process standards
Facilitate and direct production teams to efficiently process commodity dairy products to meet internal customer order requirements within management performance parameters ensuring adherence to defined Product Specifications, Quality and Safety Standards.
Management of new/improvement projects towards timely, effective and efficient implementation and commissioning of equipment / process and product
Active involvement in installation and commissioning of new machines and process
Preparation of Project briefing document for improving the existing process and product as well as for expansion
Involved in HARA (Hazard analysis and Risk assessment) for the project
Leading the Project installation and commissioning activities
Coordination with the other department during installation and commissioning
Responsible for successful completion of product trials and commercial production on the new equipment ensuring no snag pending at the end of the project
Responsible for facilitating SOPs related to the project and in turn ensuring training of the production staff and operators
Managing the implementation of new equipment and process through validation programs
Working with Continual Improvement team for product NCN’s, product complaints, root cause investigations and corrective actions
Ensuring corrective actions are implemented and measures are incorporated into quality system to prevent recurrence and Working towards zero product on hold status in DQR
Ensuing the adherence to procedures through audits and updating SOPs whenever necessary.
Key member of HACCP team; Involve in HACCP study of all cheese products and services
Certified AIBI Auditor and Internal ISO auditor
Ensuring no impact on product quality post CIP optimization
Managing Control / Ensuring hassle free operation of UHT plant, vacutherms, Corazza, Trepko, Weigh pack jar filling and FMC can filling lines
Conducting trainings for key operators for process optimization
Validation of the P&I diagrams and process design
Study and validate PID
CIP validation
Follow up of hardware and software related project snags
Participate in the control and minimize wastage of materials, product, consumables and chemicals to achieve budgeted targets
Improvement in ingredient LIPs to targeted levels
All blending batch meeting targeted requirements
Involve in the commissioning of new projects
Conduct training for the operators during commissioning
Liase with process team manager and CIT for investigations of non conformance and identifying the
corrective and preventive actions
Assist manufacturing team in continuous improvement and problem solving
Prepare and maintain proper document compliance
Commission of new equipments by I/O checks, water and product trials
Conduct process and CIP validation of new equipment
Involve in online troubleshooting by identifying the exact root cause
Maintain Health and safety objectives
Ensuring staff management
Maximizing utilization of available resources
Ensuring health and safety requirements are met
Zero accidents within the department
Ensuring area meets all quality requirements
Training for the production team
Process trouble shooting
Maintain record keeping as per the standard operating procedures
Completed the graduation with first class grade Got exposure to theoretical and practical experience in the university