FAKHARUDDIN AGHA

• Worked with Japenese consultants to Ensure Smooth material supply chain related to CKD, Local, Consumable and technical stores, Spares & paint stores, to achieve budgeted production, following 4M.
• Monitored CKD shipment, Ware housing, process layout, item movement in accordance HSE system requirement.
• Analyse ways to optimize 5S, JIT supply & lot wise supply system monitoring. Train, evaluate & empower team.
• Timely prioritize Logistics, arrange shortages, report abnormalities via SAP system & GLIMS to H.O for Claims.
• Coordinate with after sales to maintain safety stock, timely fulfilling of parts that ultimately satify the customer.
Local & Consumable Store: Support production, aligning variant wise material supply ability, to Body Paint & TCF lines.
 Improve CBP reordering, discourage excess procurement. Follow FEFO and FIFO. Fully focused towards deliverables.
 Monitor long unconsumed Aging-items to optimize reordering. Reduce financial burden to 20% in over inventory.
Warehouse/Logistics: Equipment Selection, like trollies, stacker, motorized pallets, racks, Lifters & Tow truck to improve movement in Warehouse and to utilize max: available area, study making lay out zones wise flow, model wise.
 Optimize space for CKD & Localize parts Store in Warehouse by 20%, revising safe stacking Model, part wise case weight and size wise with vertical layers. Improve safe, swift logistics, unboxing. Steel ramp for multisite offloading.
 Print and paste Kanban, for batch identification. Proposed WHIMS, & scanning sensor at in-out gates.
Inventory Stock: Discourage over stock & manual posting- verifications; add features of Auto Notification, in SAP system.
 System based recording and labeling of controlled items storage and issuance, followed as per APS & DPL.
 Save to a Million, plug leakages in consumables materials, gas fuel supplies consumption & scrap categories.
 Devise SAP/system based digital receipt to generate in-out AS & VD Ledger, to support Audit reconciliation process.

• Independently managing the machining production unit, from PPC, SC to dispatch. Administer 400+ workforce.
• Reduce 40% wastage. Improve 10% productivity through planning, training & monitoring for effectiveness; use of tool and machining parts. Reduce machining time & save cost through operational time study.
• Conduct kaizen studies in process areas (value stream mapping). Improve OLE and Employee Empowerment.
• Strengthen all support/maintenance departments to resolve issues of production machines and keep the parameters intact to minimize the downtimes & deviations in delivery plan. Also take care of foundry supplies.
• Strengthen QA dept: to ensure inspection, testing through Gages to make product up to mark & defect free.

Achievements:
 Monitor consumables, consumption of energy, O.T, cost & utilization. Rs-3.0 Million Savings on 3M control. Standardize wastage.
 Prepare budget performance format. Develop TEAM, enhance capacity i.e saved 02-days/Month. Enhance 30% sales revenue.

Responsible to Look after all PRINTING AND PACKAGING production related matters of two plants having 250 employees. All internal Factory issues like manpower deployment, quality, purchase, stores, up keeping of machines, process parameters and relevant standards to be followed for customer satisfaction within ISO environment. Keep the three plants in good running capacity for different manufacturing processes, like cold extrusion for Aluminum, hot extrusion for PE tubing, and laminated tubing on automatic machines.
Revive injection molding plant successfully with best utilization.
Replace old molding to latest energy efficient machines.
Propose recycling and mixing with fresh resin.
Optimize results through material and machine Planning. Project Plan to make in house mold making workshop.
Accommodate excess workers in different areas on the basis of skills and their interests to balance and economize the manufacturing cost.
Kill unnecessary overtime and save considerable amount to strengthen financial status of company.
Develop working stability within capacity, by revising the market compatible wages, required for satisfactory output.

 Improve 40% record productivity/month, with record 20% high sale. Strengthen scheduling & supply chain.
 Flexible planning of 7- color printing machine, save 10% printing ink and cost of changeover blocks.
 Reduce WIP to 50%, coordinating with marketing & SC. Organize in house injection molding machine plant set up.
 Control budget through progress indicators reporting and suggest ways to improve process area.

Manage all factory issues related to Production, Administration, and Quality, planning, stores and purchasing, security, Maintenance activities from CUT to PACK. Look after garment spec and SMV deviation issues.
Independently run the Factory with the best capacity utilization. Managed more than 500 workforces, from stitch to finish and get 7500 garments per day with 250 machines. Fairly delegate the authorities to each respective level to get work effectively.Control production cycles and reduce the cost. Justify and defend the budgets require to manage and achieve factory targets. Monitor the expenses to ensure sound financial responsibility. Support HR activities.

 Improve 100% sewing production, volume from 100K to 200K garment/month in six month period through material planning & scheduling priorities for basic 5-pocket jean pant with 250 machines.
 Reduce 5% cost of cutting blades studying in-contact area consumed during cutting denim fabric.
 Optimize 7% cutting production through planning, process value mapping and team building.
 Optimize time 10% in sewing by adding machines for over burdened operations during time study, reduce movements.
 Categorizing rework area with color basket for identification near cropping/trimming, rivet buttoning.
 Categorizing separate area for garment shade matching and variations received from washing.

Responsible to efficiently run the laminate tubing plant with ISO standards. Maintain machines and quality to deliver good quality products to the customers. Deal day to day issues within plant with respect to deployment, over time, planning, procurement and administrative issues.

To assist Manager Production in running HOT DIP GALVANIZING COATING OF MS PIPE Plant.

• To ensure the supply of raw material to the plants and co-ordinate in planning according to plant capacities considering urgent market demand and sales.
• Monitor pipe galvanizing production processes including chemical treatment, analyze the process deviation.
• Keeps the workers become committed to their work instructions and ISO standards.
• To control the pipe & process (pickling, fluxing, galvanizing) specifications in accordance with the relevant recommended parameters and standards.
• Ensure storage of all WIP material and scrape in designated storage areas.
• Reply NCR/complaints for maximum customer satisfaction and support taking corrective and preventive actions.
• To make arrangement for purchasing raw material as per annual and monthly budget of plants.
• To ensure the effectiveness of information system by analyzing the status of stoppages of plants.
• Save 4% of imported Item consumption, minimizing wastage and efficient handling of bi-products.
• Work for the Certification of Environment Management System ISO 14001.
• Work for fume scrubber system to protect our environment from pollution.
• Took an active part in the installation of new Australian Galvanizing Plant.
• Work with the JUMO Software to record the kettle temperature.