Production and Process Improvement - Team Leader
Fosroc
Total years of experience :12 years, 8 Months
• Managing a team of 30 people on the shop floor, including 4 shift supervisors to ensure that the production plan is executed on time and the daily target of 33 metric tons is achieved.
• Send daily and monthly production reports to the Operations and Production Manager.
• Conducting ABC analysis of fast moving finished goods by looking at past 12 months sales data and assisting the Production manager in creating a weekly production plan.
• Calculating monthly labor hours and sending the overtime report to the Accounts department and Operation Manager and citing the reasons for the increase or decrease in labor hours.
• Training the workers on the shop floor to use proper ergonomics to reduce fatigue and increase productivity and maintaining the OEE above 65% by maximizing output and ensuring the automated filling lines are always running.
• Checking stocks of fast moving goods and ensuring safety stock levels are always maintained.
• Assist the Production planner in the planning process whenever there is a sudden spurt in orders and also act as an ad hoc production planner in his absence .
• Communicate with the Production Planner and the concerned Customer Service representative whenever there is a delay in production.
• Ensure HSE rules are strictly followed on the shop floor without compromise.
• Ensuring Production supervisors have conducted preventive maintenance of machinery and personally check to ensure machines are properly maintained.
• Coordinating daily with the Material Planner to ensure timely availability of the raw materials.
• Weekly stock check of all the raw materials to ensure that the book and physical stock tally and variances are kept under check.
• Coordinating with the maintenance department for weekly preventive checks and in case of machine breakdown.
• Checking the flammable storage area to ensure the raw materials are stored under HSE norms.
• Reprocessing of expired or non moving goods by coordinating with the quality control department.
• Issuing, picking and posting of batch cards on Microsoft Dynamics.
• Maintain OTIF above 95%.
• We have been awarded the best operations team in the FOSROC group, in 2015 and 2016.
• Conducting the ABC analysis for all products, using the sales data for the past 12 months and creating a weekly production plan based on the analysis. And forecasting demand using Time- Series analysis, by including seasonal variations in demand for various products and removing noise from the data using MS Excel, and also considering the present market demand through interaction with the sales team .
• Creation of a 3 week rolling production plan for the resin plant( product mix of more than 1000 products) and also planning daily production for the admixture plant, and ensuring daily production target of 33 tons(resin plant) is met with one automated and 3 manual filling lines, and finding the root cause if the target isn’t achieved.
• Planning production based on Sales orders placed by the CSD from various regions(UAE, Kuwait, Bahrain, Oman, Intercompany and Fosroc Global Trading) and optimizing/maximizing production and answering queries regarding lead times.
• Maintaining safety stocks of all fast moving goods.
• Creation of daily, weekly and monthly production reports, and report the cause for the deviation of production plan, if any.
• Maintaining the Overall Equipment Efficiency above 65%, by analyzing production and filling times for each product and improving ergonomics on the shop-floor and changing the overall product mix i.e. using a mix of small packages which takes longer filling time and large packages which takes less filling time to ensure tonnage target is met.
• Coordinating with the supply chain department to ensure the availability of raw materials to maintain the integrity of the production plan.
• Ensuring that H.S.E rules and procedures are adhered to, and the plant is kept clean, .
• Liaising with the Shift Supervisors to achieve the daily production target.
• Ensuring the committed date for delivery of products is met by liaising with sales, customer service, purchasing and quality control departments and informing the Customer service Manager regarding any delays.
• Maintaining inventory as per stock day targets, through JIT.
• Issuing, picking and posting of batch cards on the Microsoft DAX ERP system.
• Maintain OTIF above 95%.
• We have been awarded the best operations team in the FOSROC group, in 2015 and 2016.
Liaised with contractors and suppliers for the construction of 20000 sq. ft. hall, 5000 sq. ft restaurant and 5 cottages.
Marketing the resort to the target customers through market segmentation to increase bookings.
Managing employees in the daily upkeep and maintenance of the resort.
Ensuring high level of satisfaction to the guests by maintaining high levels of service
Production Planner and Process Improvement Engineer Jan 2015- Present
Fosroc, Dubai
1) Planning production for the resin and admixture plant and making sure that the production target for the month is met.
2) Ensuring the committed date for delivery of products is met by liaising with sales, customer service and purchasing departments .
3) Maintaining the overall inventory of finished products low through JIT.
4) Measuring overall equipment efficiency in the resin plant to increase productivity by analyzing production and filling times for each product and improving ergonomics on the shop-floor and changing the overall product mix i.e. using a mix of small packages which takes longer filling time and large packages which takes less filling time to ensure tonnage is met.
Forecasted price of petrochemicals on the Platts software using technical indicators like MACD, CCI, stochastic oscillator and RSI to help the management make buying decisions.
Involved in the implementation of the Oracle Business Intelligence software and training the sales team in its functioning.
Worked with various departments in the Organization and learned how the trading business operates. Performed process mapping and identified red flags to reduce overall time to process documents.
Updated the specifications and Material Safety & Data Sheet (MSDS) for the various products that the company trades in.
Participated in a workshop conducted by HSBC on Letter of Credit.
Participated in workshop conducted by a Shipping company on INCO terms.
Bengaluru
Interacted with clients (top management of a micro-finance company) based in the U.S.A on a weekly basis for generation of an Application Scorecard and analyze requirements.
Ensured that the weekly SLAs were met and any discrepancies found in the output were rectified.
Performed bi- variate analysis on the variables by using customer provided data.
Developed a logistic model having a rolling window using the variables by considering a one year window from the application date.
Accepted or rejected customers for credit, based on the Probability Default (PD) generated in the logistic model for the customer.
Created a Credit Policy through which the amount to be assigned and tenure was decided for each customer based on Probability Default (PD).
Refined the overall model using Trans Union data through addition of variables present in the Trans Union data.
Reduced delinquency rate by 60 percent and increased sales during Christmas.
Improved the overall productivity of Peripheral Grinding wheel by finding optimal settings for Feed rate, cutting speed and dressing frequency without compromising quality factors using Response field methodology.
Achieved cycle time reduction from 114 seconds to 94 seconds.
Created Standard operating procedures through regular interactions with the workers on the shop floor.