Quality System- Food Safety Manager
Almarai company
Total years of experience :14 years, 8 Months
Leading the Quality System- Food Safety and Hygiene department of International Pediatric Nutrition Company (IPNC), fully owned by Almarai Company and reporting to Divisional Quality Manager
Job Highlights:
Implementation of ISO 22000-FSMS, 9001-QMS and HACCP in a brand new infant nutrition plant
Conducting HACCP study of Infant formulae, WMP, SMP, RTF & UHT grade drink for pregnant women
Leading the HACCP study for new product development at site or in third party manufacturing unit
Setting or defining CCP, OPRP for different process or product by conducting hazard risk analysis
HACCP reviewing of CCPs, OPRPs and all other HACCP modules as per annual review plan
Facilitating internal and external AIB Inspection as per the annual schedule and reporting
Appearing as Lead Auditee in annual external audit of ISO 22000 conducted by Assure Quality, NZ
Setting microbial testing parameters for each raw materials to ensure finished product specification
Ensuring critical process parameters to Food Safety, Hygienic condition and GMP to maintain standard
Facilitating investigation of Food Safety related issues or complaints, report writing on RCA and CAPA
Establishing and monitoring the Zoning and Gowning practices in different production floor
Setting hygienic guidelines & monitoring critical process activities in order to control microbial hazard
Conducting and reviewing of HARA (Hazard Analysis and Risk Assessment) for any changes in plant
Planning and implementing microbiological swab samples of area as per Environmental Monitoring plan
Facilitating Internal Audits in cross functional departments to check compliance to ISO22000 standard
Managing the internal laundry facility in order to maintain uninterrupted supply of critical care gowning
Conducting compulsory trainings on CCP, PRPs, OPRPs, GMP, GHP to all employees working in plant
Maintaining pest control activity at site and facilitate a pest free manufacturing environment
Conducting mock recall exercise as per the annual plan and complete with in the defined time frame
Involving actively in any Crisis Management requirement of any Food Safety or Food Defense issue
Preparing and maintaining annual departmental budget for Quality-Food Safety & Hygiene team
Maintaining departmental annual consumable consumption, head count with cost reduction initiatives
Accomplishments:
Successful launching of new products SKUs in market after passing through several testing and controls
Successfully completed IRCA approved ISO 9001:2015 training and developed as certified Lead Auditor
Successful completion of annual surveillance and re-certification audits without any major findings or NC
Attained highest degree of consumer satisfaction 2015 by reducing complaints to 0.45 CPM from 3.4 CPM
Achieved overall First Time Quality (%FTQ) up to 98.5% against the target value of 98.0% in 2015
Succeed in maintaining Factory Hygiene Rating (%FHR) at 99.8% against target value of 99.0% in 2015
Achieved zero level of product recall or withdrawal due to major Quality and Food Safety issue since 2014
Successful transition from ISO 9001:2008 to ISO 9001:2015 with in the defined time frame by August 2016
Job highlights-
Planning, scheduling and organizing Process, Manpower and Raw materials as per the production plan
Handling all shift activities with the department and managing manpower in order to achieve the target plan
Implementation of Quality and food safety standards as per the Infant food standard and maintain them
Facilitating HACCP implementation and maintaining CPPs and OPRPs as per the HACCP plan
Establishing training for the new staff members on different production activities and line walks
Active member and working as champion in HACCP team and involve in all HACCP study
Formulating Standard Operating Procedure for different activities in the operation of Infant food formula
Enforcing and maintaining the strictly Health and Safety guidelines to avoid any Health and Safety issues
Accomplishments:
Successful reduction of Can filling average Loss In-process (LIP %) from 15.39% to 5.18% by applying a successful Six Sigma Project
Successfully increased the machine efficiency (OEE) from 65% to 85% within one year from the plant initial startup with Product Qualification
Implementation of A3 Business case in IPNC and mentor technical team on Structured Problem Solving Tools (DMAIC, 5 WHY, Fishbone, Pareto Analysis)
Successfully optimizing the man power requirements for production by developing multi-tasking team with in the department
Pro-actively identified Quality and Food Safety issues in Dry-mixing and packing facility in order to reduce the defects or non-conforming products and increasing the overall yield up to 97% from 95%
Job Highlights:
Started with UHT milk aseptic processing and filling and working as a Dairy Technologist and supervising
Chosen as shift supervisor in Cheese Plant-UHT Processing and Filling plant to manage lack of supervisors
Planning, scheduling and organizing process and resources- manpower and raw materials as per the plan
Selected as Dairy Technologist in ‘Project Cradle’- a project for manufacturing baby food products
Worked with Project team and actively involved in plant installation, commissioning and qualification phase
Involved with the Automation team to carry out FAT (Factory Acceptance Test) on site prior to installed
Involved in machinery layout designing and hygiene zoning separation according to the process flow
Verification of P&ID (Process and Instrumentation Description) with the actual installation and update
Worked as an active HACCP team member in the initial Pre-HACCP step and involve in HACCP study
Prepared snag list and follow up the completion with GEA- Denmark project team and report accordingly
Involved in minor or major changes requirement in projects based the process future aspect and feasibility
Formatted Standard Operating Procedure for a brand new plant of milk powder and infant nutrition formula
Established training program for the new staff members on different production activities and train them
Involved in activities of Installation Qualification-IQ, Operational Qualification-OQ, Product Qualification-PQ
Accomplishments:
Handpicked by top management for the brand new Project of manufacturing baby food product, named as Cradle Project, latter on turned as International Pediatric Nutrition Company (IPNC) - a joint venture between Mead Johnson- USA and Almarai Company-KSA in 2010
Allotted by the company for a 20 days in plant training in an Infant food manufacturing plant of Mead-Johnson Nijmegen, in Netherland to develop similar operation and quality facility in IPNC plant
Enthusiastically contribute a as team player in Successful Commissioning of brand new infant food plant; Installation Qualification (IQ), Operational Qualification (OQ), Product Qualification (PQ)
Worked in a team in successful handover of project well within the time frame to IPNC management
o Joined in February 2016 and expected completion by end of the year o This course covering all aspects of Food Quality Assurance and Quality Control in food industry
B.Tech degree in Dairy technology with internship. Area developed: Cost Reduction & Resource Management *Material management and sock controlling. *Spearheading value analysis continuous improvement initiatives in process. *Implementing strict measures in operating procedures to optimize resource/capacity utilization. Quality Assurance *Implementing ISO, HACCP, GMP and SOP for maintaining quality standards and also handling other relevant documents *Identifying areas of quality failures and take steps to rectify the system. *Practicing quality standards with key emphasis on improving quality. *Documenting and maintaining ISO, HACCP, and GMP. Man Management *Leading/motivating teams ensuring their career development and planning materials & spares. * Train the subordinates for better understanding the operations, hereby-ensuring optimum performance. *Determining the manpower requirement in accordance with the manpower rationalization and production norms. * Strong Focus on Health & Safety in workplace