Process Lead
Syngenta Pakistan Limited
Total years of experience :15 years, 0 Months
• Process Design and managing process efficiently
• Lead the Process Risk Assessment of FF&P processes
• Lead the hazardous area classification and its compliance
• Coordinate operation excellence initiatives such as Overall Equipment Efficiency (OEE) enhancement, Variable Product Cost reduction, Manufacturing cost monitoring and Visual Factory, 5s, Lean Principle implementation and traffic management initiatives
• Lead and coordinate Compliance of Management of Change
• Lead Process, improvement, site modification and capital investment projects as a project manager
• Selection of new equipment and machinery
• Preparation of capital investment proposals and budget management
• Assist site manager in developing site strategy and implementation of cost efficiency targets for the site as member of the site leadership team.
• Report HSE performance / KPIs monthly and conduct incident & accident investigation
• Lead Health risk assessment, Workplace risk assessment management of change system as a coordinator for site.
• Conduct HSE inspections and lead HSE audits as per Code of practices and HSE standards
Carried out root-cause incident investigating and problem solving techniques by using 5 whys/ what if/ fault tree diagram and Fish born etc.
• Member of RIRA (Residual Impurity Risk Assessment) team and assist in validation protocol.
• Assist in development of new processes, formulations and filling and packing activities and in simplifying the old ones
• Develop P&IDs, process flow diagrams and engineering drawings
• Ensure site personnel are trained and recognize their role in HSE and Process Safety management
Additional Assignments
Production Excellence Lead, Pakistan
• Lead PE initiatives in coordination with regional PE team
• Responsible for the Production Planning & detail scheduling (PP&DS) within production assets
• Responsible for weekly production scheduling to the full execution of the MPS (Master production schedule).
• Responsible to utilize assets effectively
• Responsible for scheduling required packaging materials and components to produce finished good as per plan and issue PO to vendors.
• To provide demand visibility to vendors to drive supply reliability and to reduce lead times
• Coordinate reworking related works and ensure the efficiency of rework process.
• Production order fulfillment analysis and summarization for continuous improvement.
• To actively participate in the resolution of issues related to PP (production planning) and MRP (material requirement planning).
• To lead ROP meeting on monthly basis.
• Maintaining a balanced rough cut capacity plan for a minimum of 0-12 months and a detail weekly capacity plan over the short-term, in order to meet the requirements of asset production & supplier scheduling
• To maintain & reflect agreed data in SAP for manufacturing lead time, process reliability and capacity availability
• Control and manage production plan, activities, material flow to support production line smoothly in order to avoid downtime.
• To ensure the effective introduction of new SKUs and bulks, includes BOM, routings etc.
• Assist warehouse to set up material safety stock reasonably, work with team to achieve inventory target.
• Implement Syngenta HSEQ policy at suppliers end
• Managing Toll manufacturing in Pakistan
Additional Assignments
Production Excellence Lead, Pakistan
• Lead PE initiatives in coordination with regional PE team
Packaging Champion, Pakistan
• Lead packaging development initiatives (new development, cost saving project, etc.)
• Responsible for planning and implementation of production plan, as per sales forecast for timely availability of the products.
• Overall responsible to maintain product quality standards & HSE standards in my area of responsibility
• Effective utilization of available resources to achieve desired productivity and quality standards
• Co-ordinate with other functions like QC, Engineering, Warehouse, Operations to ensure product availability as per agreed supply plan
• Responsible to supervise all Chemical Process and formulation, filling & packaging activities
• To monitor OEE of FF&P lines and do analysis for its improvement
• To monitor the performance of Incinerator, Packaging and filling Machines and charging pumps of the Plant
• Job allocation to workmen
• To prepare and update Bill of Material & Routings
• To prepare and update Standard Operating Procedures for all production operations.
• Raise MIR for timely issuance of materials from warehouse
• Maintain complete documentation and record of all production activities, such as Formulation/packing Log sheets, shift report, MIR, FDN, wastage report, activity break-down record, incineration report, noise level, velocity/ventilation check, etc.
• Supervise waste management activities like waste incineration, washing of contaminated drums/containers, water treatment & drum crushing
• Monitor material consumption variances to control wastages within set targets
• Risk assessments of all production activities
• Implementation of FAO and WHO standards of pesticides
• Testing of finished product, auxiliaries and Active Ingredients (Using all testing equipment like HPLC, GC, Spectro, Lovibond, particle size analyzer, Karl Fisher titrator etc.)
• Development of Analytical method of the pesticide product
• Analytical and RIRA testing method validation
• Process validation
• Development of RIRA Chart based on RIRA software
• Testing of Packaging material (Bottles, Carton, flexible packaging etc.)
• Development of new packaging and preparation of specification sheet to get approval of regional packaging team
• Packaging Compatible studies of new products and development of their packaging profile and packaging Instruction by using CAP software for regional approval
• Preparation of SOP on regional format
• Training of shop floor workers on quality
• Health risk assessment, job safety analysis of lab activities