Production Manager
Sameer Agriculture & Livestock Ltd
Total years of experience :21 years, 6 Months
• To ensure that all primary and secondary products are manufactured to fulfil internal customer requirements whilst achieving laid down quality standards and product plans. By ensuring that all necessary resources are available and utilized in a safe efficient manner .
• Managed the Aseptic Filling & Pkg of UHT product -Juice, Plain Milk, Flavour Milk, Milk drink Milk & Fermented product -Drink Yoghurt on Procomac Filler and Tetra Filler.
• Managed the Blending & Processing of different types of Milk (Plain Milk, Flavour Milk & Flavour Milk drink ), Juice of different variants and Fermented Milk ( Yoghurt drink ) through standard operating procedures
• Co-ordinating processing activities ensuring all HACCP & GMP techniques are applied
• Analyzing various processes / applications and recommending process modifications and equipment calibrations to enhance operational efficiency
• Developing new process concepts for production optimization, yield improvement and formulating guidelines for the sequencing of manufacturing in terms of cost cutting tools.
• Directed & scheduled preventive maintenance of plant & filling machines- daily care, weekly care, monthly and annually to maintain the health of equipment, UHT (GEA), TFA (Tetrapak- High speed), Procomac Aseptic Filler & DE Machine (GEA-500 BPM), Aseptic Pouch Fillinh machine (ESL) to minimize the breakdowns and maximize the efficiency
• Assiting Product Development Team for conducting new recipe trials according to the prescribed quality parameters
• Ensuring 100% Safety Standards, Personal Protective Equipment compliance to achieve site KPI’s of 0 accident (issuing work-permit )
• Engaged with the HR team for manpower awareness program and On-job training, skill matrix development
• Sustaining the existing network & managing the supply chain, ensuring timely distribution by monitoring availability of stock, making appropriate arrangements to ensure on-time deliveries of the merchandise
• Effectively conducting daily operational review meetings with production, engineering & quality team; presenting production actual KPI verses target KPI viz Overall Equipment Effectiveness (OEE), Yeild Loss, overfill, FG quality Status and Improvement action plan
• Providing leadership input to prepare Standard Operating Procedures, manuals & work instructions for production operations of unit; making effective use of cost analysis tools in support of strategic sourcing process, procurement costs, cost reduction metrics and bottom line performance indicators
• Analyzing various processes / applications and recommending process modifications and equipment calibrations to enhance operational efficiency
• Conducting Rootcause analysis of breakdown, Qualitydeviation, safety Incident, yield loss, low efficiencies of Machine and performance gap by advance analytical tools Fish bone analysis, cycle time reducation study, 5 whys RCA, Techanical risk assessment -FMEA technique.
• Developing new process concepts for production optimization, yield improvement and formulating guidelines for the sequencing of manufacturing in terms of cost cutting tools
• Assiting Research & Development Team for conducting new recipe trials according to the prescribed quality parameters
• Ensuring 100% Safety Standards, Personal Protective Equipment compliance to achieve site KPI’s of 0 accident (issuing work-permit )
• Engaged with the HR team for manpower awareness program and On-job training, skill matrix development
• Administered and coordinated with different section to guarantee the daily/weekly production target by managing the UHT Processing, Aseptic Filling and Packaging of different varieties of UHT Juice through standard operating procedures
• Ensured execution of quality standard & protocol to deliver finished goods considering the highest level of quality and hygiene standards
• Monitored and revalidated all pre-processing, processing and filling equipment CIP effectiveness
• Monitoring adherences to Quality system such as ISO 22000-HACCP, FSSAI and QRMP
• Guaranteed that Site Quality Management System works properly and GMP Audit are conducted on timely basis
• Directed & scheduled preventive maintenance of plant & filling machines- daily care, weekly care, monthly and annually to maintain the health of equipment TBA 8, TBA19, TCAP47, TCP70, TSA46 to minimize the breakdowns and maximize the efficiency
• Executed the preventive maintenance schedule on interval basis like - liaising with maintenance of Tetra UHT & Tetrapak Filler -TBA8, TBA19, Straw Applicator, Cap Applicator with maintenance team and non-conformance notes with regard to performance of instrumentation/ material handling equipment
• Developed and scheduled production/ packing plan and operated on resources according to the market demands and based on equipment availability
• Recruited action to prevent the occurrence of any non-conformity related to product, process or quality system
• Guaranteed that all the required raw materials are available as per production plan and machines & equipment are ready for safe and efficient operation
• Observed operational excelleance of entire production operation and Implementing operational excellence program (KPI-Safety, Quality, Conversion cost, yeld loss, Ovrerrun of Icecream ) by adhering to leader standard work
" Company Profile: - Almarai Company is the 5th largest Dairy & Food Processing Company in the world with a herd of 73, 000 livestock and a market share of 49% of the fresh dairy & processed food markets in the Gulf Region. Processing more than 2.3 million liters of pure cow milk every day equipped with state-of-the-art equipment, managed entirely by mixed of Asian and European expatriates.
KEY DELIVERABLES
Supervise the processing of UHT Milk, Fresh Juice , Flavour Milk, Fermented Milk Product like yougrt, Laban Full Fat & Low Fat and Feta & processed Cheese through standard operating procedures.
Maximise service to internal customers to meet the budgeted UHT production plan.
To Follows up with purchase and stores for availability of RM, PM according to production targets.
UHT - 10 Production lines SIG COMBIBLOC Filler and 5 sterilising plant, Overall knowledge of the processing and sterilisation operations and aseptic filling technology.
Supervise the processing of different varites of Fresh Juice through standard operating Procedures.
Optimise UHT product quality to ensure that products meet laid down product specifications.
Liaise with UHT Maintenance / Automation team through maintenance requests and non conformance notes with regard to performance of instrumentation/ material handling equipments.
Liaise with supply team to ensure all raw materials are delivered in a timely and efficient manner. Liaise with planning and filling areas to optimise production runs and minimise lost of packing time
Ensure that all products are manufactured to fulfil internal customer requirements whilst meeting agreed quality specifications, by the resources available and utilized in safe and efficient manner.
Ensure that all the people are assigned their respective jobs and that they are executing them accordingly
Manage Preventive maintenance schedule of Plant & filling machines, for minimizing the breakdowns and maximizing the OEE.
Ensure Overall equipment efficiency, process parameters, quality, safety is as per the expectations
Controlling of daily product losses & manufacturing cost by putting in place, measures and monitoring system to optimize the product yield and reduce wastage, thus establishing a continuing improvement culture throughout the department.
Manage the entire operations team in shift (employees + contractors).
Participates in health, safety and environment programs and ensures 100% HS&E compliance in shift.
ACHIVEMENTS
At Almarai, conceptualized & implemented pictorial SOP in Operation.
Implementation of PPPI modules with coordination of SAP Team
Effectively prepared weekly and monthly reports and presentations
Conducted more than 25 GMP audits in the Operations division.
As a sensory panellist, judged, analyzed and gave improvement ideas during new product development and changes in the existing recipes.
TRAINING/WORKSHOP ATTENDED
Advance HACCP
Internal GMP auditor
ISO 9001: 2008 & ISO 22000: 2005
Effective Supervisory Skills
Interpersonal Skills
Problem solving & Decision making
Effective Time Management
" Planning, and scheduling production/ packing plan and utilize resources according to the market demands and based on equipment availability.
" Managed shop floor activities of Table /white butter, Ghee & Flavour milk Production and Packaging, inventory management.
" Managing a team of around 85 workmen per shift in a 3 shift staggering arrangement.
" Ensuring that all the required raw materials are available as per production plan and machines & equipment are ready for safe and efficient operation.
" Ensure that raw material, packing material and manpower availability is complying with specifications/requirements and report if any deviations, to the Manager for immediate corrective action.
" Coordinating with the Managers for any changes or revision to the plan and accordingly make necessary changes to the production lines.
" Supervising the process to make sure that all HACCP techniques are applied, monitored and documented efficiently.
" Involve in Process improvement projects for proper utilization of utilities and for better cost management through energy conservation, and CIP Process Optimization by reducing CIP timings and chemicals usage.
" Follow up Production preventive maintenance schedules regularly and ensure all the PPM schedules are completed within the schedule timings.
" Maintaining smooth production with the responsibility of resolving issues and challenges related to Machinery, Material, Quality and a Multitask workforce.
" Managing Production operations team of malted milk & Dairy section on the shop floor, for manufacturing various powder products like BOOST, MALTOVA, VIVA, COMPLEAT, MALPA for reputed brand of GSK (Glaxo smith kline consumer Healthcare) beside other dairy products SMP, WMP, GHEE for reputed brand of Milk Foods Ltd.
" To investigate, determine and implement corrective actions to continuously improve product quality and avoid repeatable Quality incidents.
" Complete and forward production / quality / efficiency reports at agreed schedules in absence of Packing Manager.
" Maintain record keeping as per the standard operating procedures by regular checks on all operation logs
" Initiate action to prevent the occurrence of any non-conformity related to product, process or quality system.
" Managing operations for the manufacturing of milk and milk products e.g. market milk, Mother Dairy milk, Dahi, ghee, etc. under the brand name VERKA.
" Control of the chemical, physical and microbiological parameters during the processing of milk into dairy products.
" Proper packaging, storage and transportation of finished goods.
" Coordinating between Production/QC/Engineering for improvement in existing processing system.
" Involved in Manpower rationalization project.