Factory Manager
Araak Group
Total years of experience :17 years, 3 Months
Project Management:
Lead a 2M+ USD Greenfield Project for Food
Processing and Packaging. Key responsibilities included
- Site Selection: By identifying factors of strategic signifi cance from a list of potential places.
- Preparation of Factory layouts for civil design.
- Equipment/Machinery Selection and Procurement
- Budgeting and Scheduling of the construction phase.
- Utilities Planning for Factory Site: Preparation of piping diagrams.
- Oversaw Erection and Commissioning of Plant Equipment including packaging lines and utilities.
Implementation of Odoo ERP:
- Lead the implementation of Inventory Management, Manufacturing
and Quality Modules.
Factory Operations:
Leading a team of 15 direct reportees and a total team of 50+ people. Key responsibilities include
- Supply Planning based on demand forecast
- Production Scheduling
- Predictive and Preventive Maintenance Planning
- Manpower Management
- Implementation of 5S and TPM methodologies
- ISO-22000 FSMS development and implementation
- Lead complete Production and Maintenance Operations of Fried Snacks Manufacturing Factory (Potato Chips, Peanuts and Nimco) at Hub Industrial Area.
- Managed a large and diverse team of 20 direct reportees and 500 contractual workers.
- Major Achievements:
- 10% Reduction in FOH cost per kg resulting in a YTD saving of PKR. 11.4 Mn.
- 35% Reduction Packaging Material Wastage, reduced from 2.83% to 1.80%. YTD cost saving of
PKR 0.80 Mn.
- 10% Improvement in Labor Productivity (Kg/Man-hrs).
- 3% Improvement in Process Yield; increased from 24.8% to 25.7% (YTD).
- 75% Improvement in MTBF; increased from 9.72 to 17.00 hrs.
- 35% Improvement in MTTR; decreased from 0.83 to 0.53 hrs.
- Streamlined Annual Capacity Planning through preparation of Annual Operating Plan (AOP) and
Supply Planning Schedules as per Rolling Sales Forecast (RSF) for Pre & Executive S&OP.
- Optimized Process Parameters and improved OEE% of Packing Machines from 76% to 83% through
effective use of Loss Tree Analysis and other TPM and Lean Manufacturing techniques.
- Prepared Capital and Revenue Budget for the factory. Achieved 6% saving on Revenue budget over
the target via improved Autonomous and Planned Maintenance programs.
- Lead complete production operations of Biscuit Manufacturing on 7 lines with over 30 packing machines.
- Managed a large team of 18 direct reporting permanent employees and over 1000 contractual workers.
- Major Achievements:
- 14% reduction (175 workers) in on-roll strength through exhaustive time and motion studies,
achieved a gross annual saving of PKR 40 million.
- 40% reduction in Thermal Printing cost, equivalent to a saving of PKR 20 million/annum through
optimization of coding format.
- Increased Labor Productivity from 17 to 21 Kg/Man-hr over three years.
- 15% Reduction in Packaging Film Wastage in 2014, equivalent to an annual saving of PKR 12
Mn.
- Reduced Finished Product Wastage by 16%.
- 18% reduction in Process Downtime from over three years.
- Conducted an extensive study on un-traced wastages with Finance Department to improve
manufacturing cost accounting. Unaccounted losses reduced by 25%.
- Reduced the giveaway (over weight product) loss to 0.2% through active use to Statistical Process
Control (SPC).
- Customer complains reduced by 30% over three years.
- Lead the Annual Capacity Planning process at Group Level, and prepared Annual Operating Plans,
(AOP) as per Rolling Sales Forecast (RSF), thereby improving capacity utilization from 87 to 92% over three years.
- Rolled out Supply Planning Schedules for Pre & Executive S&OP.Achieved an Output Reliability Rate of 95% through continuous liaison with sales and logistics team to optimize supply planning
schedules.
- Optimized process parameters; set up a system for measuring OEE% of Packing Machines. Achieved an OEE of 83% on most machines.
- Maintained safe working conditions at the plant by complying to the occupational health and safety rules.
- Administered quality and SHE related matters at 3P sites for Detergents, Personal Products and Tea, and implemented Unilever Global Quality Standard for co-packers across all 3P makes units.
- Drove strict adherence of all manufacturing process with
- HACCP Guidelines
- Unilever OHS FWS/OHSAS 18001:2007 Compliance.
- EMS FWS/ISO 14001:2004 Compliance.
- Lead the implementation of CRQS program, Quality Verification Program (QVP) and Enzyme Safety Protocol on Detergent Plants.
- Performed Internal/External audits of Unilever factories/offices on nationwide basis.
- Major Achievements:
- Developed and Implemented measurement and monitoring regime for Environmental KPIs across all 3P sites.
- Preparation of system procedures for environmental aspect impact assessment and training.
- Successful completion of annual quality and safety audits with successful renewals of certifications from independent third party auditors.
- Oversaw the erection of 400 Tons/Day Detergent Manufacturing Plant for HSE related matters with Zero Lost Time Accidents during the course.
- Independently Lead Shift Operations Production Planning and Operations Management of Liquid Line
(Pasteurization and UHT) and Powder Plant.
- Prepared & maintained daily report on schedule adherence and productivity status.
- Minimized performance bottlenecks for achieving high productivity with minimum consumption of
material & machine.
- Supported the adherence of HSE and Food Safety Rules Compliance.
- Major Achievements:
- Successfully implemented a system for filling machines’ efficiency monitoring in 2008.
- Performed the role of Project Coordinator (Processing) for installation and commissioning of 2nd
Milk Pasteurization Plant.
- Commissioning of Third Aseptic Tank (ATS) with GEA TDS in 2007.
- HPO Storage and Dosing System as Project Team Member (Process Design).
• Shift Incharge on UOP Sinco Solid State Polycondensation (SSP) Plant for PET resin up-gradation.
• Constant Plant Monitoring through Delta V DCS.
• Production Plan Execution
• Trouble shooting and Trends’ study of key controllers.
• Exposure to Zimmer GmbH Polycondensation (POLYCON) plant for PET resin manufacturing.
Studied Thermodynamics, Heat Transfer, Mass Transfer, Fluid Mechanics, Plant Design and Engineering Economics. Did 6 weeks industrial training and Final Year Plant Design project. Completed my degree in 1st Division.