Manager (Production, R&D and QC)
Green Energy Plus Production Company
مجموع سنوات الخبرة :11 years, 11 أشهر
• Responsible for overall plant based functions i.e Production and its planning, R&D, QA/QC, Plant engineering and after sales claim.
• Heading staff of 150 employees including Manager Production and Manager QA/QC.
• Prepare regular reports for owners, formulating and revising costing sheets of different types of batteries based on variation in raw materials price.
• Designing, Engineering and development of new product with different models according to JIS standards i.e MF, Hybrid and Dry charge battery, its formulation and complete setup installation.
• Monitoring and ensuring all In-coming, In-process and Finished products with material testings including Physical, Chemical and Electrical testings.
• Report variation in process controls and finding possible solutions to utilize substandard products.
• Product realization, re engineering and redesigning with respect to fulfilling customer requirements.
• Reducing battery claim from 2% to 0.19% by root cause analysis of the process defect and ensuring corrective action.
• Ensuring process improvements, 5S and Kaizen activities.
• Guiding and coaching employees by providing training, career counseling and feedback to achieve high performance.
• Managing a Quality control system for lead acid battery manufacturing in the sections including PP injection molding, Acid dilution, Alloy, Grid casting, Pasting, Assembly, Formation, Finishing line & Laboratory.
• Assuring Electrical testing of finished battery according to JIS standards.
• Accountable for the implementation of Quality Management System (i.e Control Deviation, Market Complaints, Self Inspection, SOP preparation).
• Formulating quality control plan, work instructions & check sheets for the acceptance of materials and processes.
• Ensuring quality & performance of the materials procured from vendors by controlling product non conformity and continual improvement.
• Organizing and performing quality control auditing and documentation functions in preparation for successful ISO 9001:2015 and ISO 14001:2015 certifications.
• Performing non-conformance analysis by statistical analysis tools including Pareto Analysis and Fish Bone Diagram etc.
• Monitoring product quality target levels to ensure compliance with customer expectations.
• Creating Quality Control Procedures that require additional inspection and testing requirements beyond the normal Quality System.
• Responsible for implementing Quality Control System to ensure that plate manufacturing processes (Formation, Washing, Drying, Plate Segregation, MC Assembly and Cutting) are complying with defined standards.
• Supervising 2 Quality control supervisors and 22 Quality Control Inspectors for timely assurance of standards that are being followed.
• Regularly coordinating with production concerned for process non-compliances.
• Assisting MQA in conducting planned QA-Audits for verifying the compliances of define standards resulting to corrective and preventive measures.
• Conducting daily GEMBA meeting at shop floor with quality control inspectors.
• Implementing SPC at each battery manufacturing process to reduce wastages and rejections, improving product quality and monitoring process/machine behavior on continuous basis.
• Developing and sharing daily and monthly quality reports with Production concerned.
• Ensuring that all chemical testings are being performed as per the defined frequency in Day and Night shifts.
• Maintaining master log of process deviations and reports of Non-confirming products for periodic analysis.
• Ensuring that all quality procedures are inline with the requirement of Quality Management System (ISO 9001:2015).
• Assisting MQA in conducting in-house training of quality control inspectors to improve their skill level on continuous basis.
• Verifying and revising Quality standards, Pictorial SOP’s as and when needed with the approval of MQA/GMQA.
• Checking and reviewing SOP’s for Sb % in feeding Lead and Quality of cork Spray.
• Assurance of temperature settings of GCM furnace and its accessories.
• Any modification in the design of existing mould of grids.
• Maintaining quality of Lead oxide powder by assuring the standards of Oxidation degree, Apparent density and Acid absorption value.
• Ensuring quality of pasted panels preventing from any defect.
• Reduction in the claim of paste shedding and whitish negative plate.
• Conducting process audits.
• Analyzing chemical and physical properties of formed positive and negative plates from IGO and TDO processes including their controlling parameters such as temperature, moisture, pH, acid specific gravity, current and voltage of circuit.
• To carryout chemical analysis of Lead powder, unformed and formed plates and Electrolyte using Titration method.
• Managing Inventory of Chemicals and performing instrument calibration.
• Reviewing and updating test methods and procedures according to SOP’s.
• Preparing chemical analysis report on daily basis, sharing analysis results with concerned departments, maintaining all records and update charts/graphs of all testings.
• Updating and Maintaining all paperwork related to the analysis (Calibration Log, RM and FG etc), NCR, DCRN, Deviation, CAR, PAR, SOP’s, Standards and work instructions.
• Developing and maintaining kaizen sheet and working on 5S.
• Managed a shift for Sugar production, refining, quality and losses
• Supervised 50 employees of daily shift in production department
• Kept up to date records and maintained logbook during shift
• Conducted employee performance reviews
• Examined machines and instruments up to working standards with coordination of Mechanical, Electrical and Instrumentation departments
• Ensured availability of process chemicals and their proper usage as specified by SOP’s and JSA's
• Assessed cleanliness of process house machinery for the avoidance of fermentation or deterioration of sugar by bacteria
• Coordinated with sugar godown officer for the production and segregation of R1, R2, and R3
• Assisted Shift Chemist for Production processes and Quality control
• Preparing MIN through SAP and Oracle
• Supervising Juice Clarification, Carbonation system, Pressure Filtration, and Talo-Clarification work stations
Research Project: Isolation and Separation of Proteins in Cane Molasses and Stillage • Identification of Proteins in Cane Molasses and Stillage • Synthesis of Proteins • Comparative study among Synthesized Proteins and available food proteins